Mercedes-Benz Sprinter / Dodge Sprinter. Service manual — part 190

NOTE: Seal off the line ends and connection
threads in the brake calipers with plugs. Also check
brake hoses for signs of cracks.

(5) Remove the brake caliper guide bolt (Fig. 4).
(6) Remove the brake caliper (Fig. 4).
(7) Remove the brake pads (Fig. 4).

REMOVAL - FRONT (DRW)

(1) Unscrew the cap from the brake fluid reservoir.
(2) Raise and support the vehicle.
(3) Remove the front wheels (Refer to 22 - TIRES/

WHEELS/WHEELS - REMOVAL).

(4) Remove the wear indicator cable and the wear

indicator (Fig. 5).

NOTE: Seal off the line ends and connection
threads in the brake calipers with plugs. Also check
brake hoses for signs of cracks.

(5) Remove the brake caliper guide bolt (Fig. 5).
(6) Remove the brake caliper (Fig. 5).
(7) Remove the brake pads (Fig. 5).

REMOVAL - REAR (16” WHEELS) (SRW)

(1) Unscrew the cap from the brake fluid reservoir.
(2) Raise and support the vehicle.
(3) Remove the rear wheels (Refer to 22 - TIRES/

WHEELS/WHEELS - INSTALLATION).

(4) Remove the wear indicator cable and the wear

indicator (Fig. 6).

NOTE: Seal off the line ends and connection
threads in the brake calipers with plugs. Also check
brake hoses for signs of cracks.

(5) Remove the brake caliper guide pins (Fig. 6).
(6) Remove the brake caliper from the caliper

adapter (Fig. 6).

(7) Remove the retaining spring (Fig. 6).
(8) Remove the pads (Fig. 6).

Fig. 4 FRONT BRAKE PADS

1 - DISC BRAKE CALIPER
2 - GUIDE BOLT
3 - WEAR INDICATOR
4 - DISC BRAKE PADS
5 - CALIPER ADAPTER

Fig. 5 FRONT DISC BRAKE PADS WITH DUAL

REAR WHEELS

1 - DISC BRAKE CALIPER
2 - GUIDE PIN/BOLT
3 - WEAR INDICATOR
4 - BRAKE PADS
5 - BRAKE CALIPER ADAPTER

VA

BRAKES - BASE

5 - 9

REMOVAL - REAR (15” WHEELS) (SRW)

(1) Unscrew the cap from the brake fluid reservoir.
(2) Raise and support the vehicle.
(3) Remove the rear wheels (Refer to 22 - TIRES/

WHEELS/WHEELS - INSTALLATION).

(4) Remove the wear indicator cable and the wear

indicator (Fig. 7).

NOTE: Seal off the line ends and connection
threads in the brake calipers with plugs. Also check
brake hoses for signs of cracks.

(5) Remove the brake caliper guide pin (Fig. 7).
(6) Fold the top section of the brake caliper up

(Fig. 7).

(7) Remove the pads (Fig. 7).

REMOVAL - REAR (DRW)

(1) Unscrew the cap from the brake fluid reservoir.
(2) Raise and support the vehicle.
(3) Remove the rear wheels (Refer to 22 - TIRES/

WHEELS/WHEELS - INSTALLATION).

(4) Remove the wear indicator cable and the wear

indicator (Fig. 8).

NOTE: Seal off the line ends and connection
threads in the brake calipers with plugs. Also check
brake hoses for signs of cracks.

(5) Remove the brake caliper guide pins (Fig. 8).
(6) Remove the brake caliper from the caliper

adapter (Fig. 8).

(7) Remove the retaining spring (Fig. 8).
(8) Remove the pads (Fig. 8).

Fig. 6 REAR DISC BRAKE PADS - 16

(

WHEELS

(SRW)

1 - AXLE
2 - RETAINING SPRING
3 - OUTBOARD PADS
4 - INBOARD PAD
5 - DISC BRAKE CALIPER
6 - WEAR INDICATOR
7 - GUIDE PIN
8 - DUST CAP

Fig. 7 REAR DISC BRAKE PADS - 15” WHEELS

(SRW)

1 - CALIPER GUIDE PIN
2 - DISC BRAKE CALIPER
3 - CALIPER ADAPTER
4 - DISC BRAKE PADS
5 - RETAINING SPRING
6 - WEAR INDICATOR

5 - 10

BRAKES - BASE

VA

INSTALLATION

INSTALLATION - FRONT (SRW)

(1) Install the brake pads (Fig. 4).
(2) Install the wear indicator cable and the wear

indicator (Fig. 4). Tighten to 10 N·m (89 in. lbs.).

NOTE: Do not install the brake hose twisted and
ensure freedom of movement.

(3) Install the brake caliper to the brake caliper

adapter (Fig. 4). Tighten the guide bolt to 25 N·m
(221 in. lbs.).

(4) Bleed the brake system.
(5) Check the brake system for any leaks.
(6) Install the front wheels.
(7) Lower the vehicle.

INSTALLATION - FRONT (DRW)

(1) Install the brake pads (Fig. 5).
(2) Install the wear indicator cable and the wear

indicator (Fig. 5). Tighten to 10 N·m (89 in. lbs.).

NOTE: Do not install the brake hose twisted and
ensure freedom of movement.

(3) Install the brake caliper to the brake caliper

adapter (Fig. 5). Tighten the guide bolt to 25 N·m
(221 in. lbs.)(M8 bolt) or Tighten the guide bolt to 30
N·m (265 in. lbs.)(M10 10.9 bolt).

(4) Bleed the brake system.
(5) Check the brake system for any leaks.
(6) Install the front wheels.
(7) Lower the vehicle.

INSTALLATION - REAR (16” WHEELS) (SRW)

(1) Install the brake pads (Fig. 6).
(2) Install the wear indicator cable and the wear

indicator (Fig. 6). Tighten to 10 N·m (89 in. lbs.).

NOTE: Do not install the brake hose twisted and
ensure freedom of movement.

(3) Install the brake caliper to brake caliper

adapter (Fig. 6). Tighten the guide pins to 25 N·m
(221 in. lbs.) for M8 bolt or 30 N·m (266 in. lbs.) for
M10 bolt.

(4) Install the retaining spring (Fig. 6).
(5) Install the rear wheels (Refer to 22 - TIRES/

WHEELS/WHEELS - INSTALLATION).

(6) Lower the vehicle.

INSTALLATION - REAR (16” WHEELS) (SRW)

(1) Install the brake pads (Fig. 7).
(2) Install the wear indicator cable and the wear

indicator (Fig. 7). Tighten to 10 N·m (89 in. lbs.).

NOTE: Do not install the brake hose twisted and
ensure freedom of movement.

(3) Install the brake caliper to brake caliper

adapter (Fig. 7). Tighten the guide pin to 30 N·m
(266 in. lbs.) for M10 bolt.

(4) Install the rear wheels (Refer to 22 - TIRES/

WHEELS/WHEELS - INSTALLATION).

(5) Lower the vehicle.

INSTALLATION - REAR (DRW)

(1) Install the brake pads (Fig. 8).
(2) Install the wear indicator cable and the wear

indicator (Fig. 8). Tighten to 10 N·m (89 in. lbs.).

NOTE: Do not install the brake hose twisted and
ensure freedom of movement.

(3) Install the brake caliper to brake caliper

adapter (Fig. 8). Tighten the guide pins to 25 N·m
(221 in. lbs.) for M8 bolt or 30 N·m (266 in. lbs.) for
M10 10.9 bolt.

(4) Install the retaining spring (Fig. 8).
(5) Install the rear wheels (Refer to 22 - TIRES/

WHEELS/WHEELS - INSTALLATION).

(6) Lower the vehicle.

DISC BRAKE CALIPERS

REMOVAL

REMOVAL - FRONT (SRW)

(1) Unscrew the cap from the brake fluid reservoir.
(2) Raise and support the vehicle.

Fig. 8 REAR DISC BRAKE PADS WITH DUAL REAR

WHEELS

1 - WEAR INDICATOR
2 - GUIDE PIN/BOLT
3 - DISC BRAKE CALIPER
4 - RETAINING SPRING
5 - DISC BRAKE PADS
6 - CALIPER ADAPTER

VA

BRAKES - BASE

5 - 11

(3) Remove the front wheels (Refer to 22 - TIRES/

WHEELS/WHEELS - REMOVAL).

(4) Remove the wear indicator cable and the wear

indicator (Fig. 9).

NOTE: Seal off the line ends and connection
threads in the brake calipers with plugs. Also check
brake hoses for signs of cracks.

(5) Remove the brake hose at the brake caliper

(Fig. 9).

(6) Remove the brake caliper guide bolt (Fig. 9).
(7) Remove the brake caliper (Fig. 9).

REMOVAL - FRONT (DRW)

(1) Unscrew the cap from the brake fluid reservoir.
(2) Raise and support the vehicle.
(3) Remove the front wheels (Refer to 22 - TIRES/

WHEELS/WHEELS - REMOVAL).

(4) Remove the wear indicator cable and the wear

indicator (Fig. 10).

NOTE: Seal off the line ends and connection
threads in the brake calipers with plugs. Also check
brake hoses for signs of cracks.

(5) Remove the brake hose at the brake caliper

(Fig. 10).

(6) Remove the brake caliper guide bolt (Fig. 10).
(7) Remove the brake caliper (Fig. 10).

REMOVAL - REAR (SRW)

(1) Unscrew the cap from the brake fluid reservoir.
(2) Raise and support the vehicle.
(3) Remove the rear wheels (Refer to 22 - TIRES/

WHEELS/WHEELS - INSTALLATION).

(4) Remove the wear indicator cable and the wear

indicator (Fig. 11).

NOTE: Seal off the line ends and connection
threads in the brake calipers with plugs. Also check
brake hoses for signs of cracks.

(5) Remove the brake hose at the brake caliper

(Fig. 11).

(6) Remove the brake caliper guide bolt (Fig. 11).
(7) Remove the brake caliper (Fig. 11).

Fig. 9 FRONT DISC BRAKE CALIPER

1 - WEAR INDICATOR CABLE
2 - WEAR INDICATOR
3 - BOLT
4 - BRAKE HOSE
5 - DISC BRAKE CALIPER/ADAPTER
6 - ADAPTER BOLTS

Fig. 10 DISC BRAKE CALIPER WITH DUAL REAR

WHEELS

1 - WEAR INDICATOR WIRE
2 - WEAR INDICATOR
3 - MOUNTING BOLT
4 - BRAKE HOSE
5 - DISC BRAKE CALIPER
6 - ADAPTOR BOLTS

5 - 12

BRAKES - BASE

VA