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1999-2000 BRAKES
Disc
IDENTIFICATION
WARNING: Vehicles are equipped with air bag supplemental restraint system. Before
attempting ANY repairs involving steering column, instrument panel or
related components, see SERVICE PRECAUTIONS and DISABLING &
ACTIVATING AIR BAG SYSTEM in appropriate AIR BAG RESTRAINT
SYSTEMS article.
NOTE: For Mercedes-Benz model, chassis and engine identification, see MERCEDES-
BENZ MODEL IDENTIFICATION .
NOTE: Information in this article does not apply to anti-lock brake system. For
information on anti-lock brake system, see ANTI-LOCK article.
All models use a 4-wheel disc brake system. Cable-actuated parking brakes are housed in rear brake rotors. All
models have brake pad wear indicator and differential pressure warning indicator. On diesel models, a vacuum
pump supplies additional vacuum for power brake unit. Model year 2000 S430 and S500 use electronic
proportioning to control brake pressure to rear brakes.
Before bleeding brakes, year, model and system application must be identified. This will determine which brake
bleeding procedure is used. See BRAKE SYSTEM APPLICATION table.
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2000 Mercedes-Benz SLK230
1999-2000 BRAKES Disc
BLEEDING PROCEDURE
Procedure A
1. On 1999 CL500, S420 & S500, disconnect 2-pin master cylinder switchover valve electrical connector at
master cylinder. Remove fuse No. 28 from relay box (F1). Relay box F1 is located near brake master
cylinder. Connect flat plug from master cylinder switchover valve to fuse No. 28 (input side). Connect
round plug from master cylinder switchover valve to ground. Ensure switchover valve is energized during
brake bleeding procedure.
2. On all vehicles, connect pressure bleeding equipment according to equipment manufacturer's instructions
and pressurize system to 29 psi (2 bar). Caliper bleeding sequence is RR, LR, RF and LF. If brake system
was opened downstream of hydraulic unit (brake calipers, brake hoses and brakelines), bleed
approximately 1/10th of a quart of brake fluid from each brake caliper. If brake system was opened at
hydraulic unit or upstream of hydraulic unit, bleed approximately 2/10ths of a quart of brake fluid from
each brake caliper.Allow brake fluid to flow until no air bubbles are present.
3. On 1999 CL500, S420 & S500, open bleed screw on brake master cylinder. Allow brake fluid to flow
until no air bubbles are present. On all models, remove pressure bleeding equipment. Verify master
cylinder reservoir is at proper level.
Procedure B
1. Turn ignition off. Connect pressure bleeding equipment according to equipment manufacturer's
instructions and pressurize system to 29 psi (2 bar). Connect Hand Held Tester (HHT) to Data Link
Connector (DLC) located in right rear of engine compartment. Turn ignition on. Follow instructions on
HHT display. After performing instructions on HHT display, start bleeding procedure.
2. Caliper bleeding sequence is RR, LR, RF and LF. Bleed approximately 1/10th of a quart of brake fluid
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from each brake caliper. Allow brake fluid to flow until no air bubbles are present. Remove pressure
bleeding equipment and HHT. Verify master cylinder reservoir is at proper level.
Procedure C
1. Connect pressure bleeding equipment according to equipment manufacturer's instructions and pressurize
system to 29 psi (2 bar). Caliper bleeding sequence is RR, LR, RF and LF. Bleed approximately 1/10th of
a quart of brake fluid from each brake caliper. Allow brake fluid to flow until no air bubbles are present.
2. After performing brake bleeding procedure, if brake pedal travel is too long, with pressure bleeding
equipment still connected, open bleed screw at RR caliper. Sharply depress brake pedal and hold for 3
seconds. Close bleed screw. Release brake pedal slowly. Repeat bleed procedure at RR caliper
approximately 5 times. Brake pedal travel should be acceptable. Remove pressure bleeding equipment.
Verify master cylinder reservoir is to proper level.
ADJUSTMENTS
STOPLIGHT SWITCH
Stoplight switch is located under dash, above brake pedal. Stoplight switch is self adjusting.
NOTE: On all models parking brake adjustment is necessary only when removing or
servicing rear brake discs or if insufficient braking is present after applying
parking brake.
Different adjustment procedures apply depending on year and model. See PARKING BRAKE
ADJUSTMENT PROCEDURE DIRECTION table.
PARKING BRAKE
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1999-2000 BRAKES Disc
Procedure A
1. On SL500, remove exhaust head shield to access parking brake cable adjusting nut. On all models, loosen
parking brake adjusting nut at parking brake pedal (SL500) or lever (SLK230). Loosen adjusting nut until
parking brake cables sag. See Fig. 1 . Raise and support vehicle. Remove rear wheels. Align wheel bolt
hole with parking brake adjuster. Using a screwdriver, turn adjusting wheel up on right rear side of
vehicle. Turn adjusting wheel down on left side of vehicle. Turn both adjusting wheels until rear brake
disc can't be rotated (tight).
2. Turn adjusting wheels 5-6 teeth (down on right) and (up on left) until rear brake disc can be turned freely.
Turn adjusting wheel an equal number of turns at each wheel. Tighten parking adjusting nut at parking
brake pedal (SL500) or lever (SLK230) until parking brake cables no longer sag. Forcefully operate
parking brake several times. Adjust parking brake adjusting nut until parking brake starts to apply moving
pedal (SL500) or lever (SLK230) one notch.
Procedure B
1. Preload automatic cable length adjuster. See PRELOADING AUTOMATIC PARKING BRAKE
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CABLE ADJUSTER . Raise and support vehicle. Remove rear wheels. Align wheel bolt hole with
parking brake adjuster. Using a screwdriver, turn adjusting wheel up on right rear side of vehicle. Turn
adjusting wheel down on left side of vehicle. Turn both adjusting wheels until rear brake disc can't be
rotated (tight).
2. On C-Class, CLK and E-Class models, turn adjusting wheels 12-15 teeth (down on right) and (up on left)
until rear brake disc can be turned freely. On S-Class models, turn adjusting wheels 5-6 teeth (down on
right) and (up on left) until rear brake disc can be turned freely.
3. On all models, turn adjusting wheel an equal number of turns at each wheel. Forcefully operate parking
brake several times. Parking brake should adequately apply in 10 or less notches.
Procedure C
1. Raise and support vehicle. Remove rear wheels. Preload automatic slack adjuster. See PRELOADING
AUTOMATIC PARKING BRAKE CABLE ADJUSTER .
2. Align wheel bolt hole with parking brake adjuster. Using a screwdriver, turn adjusting wheel up on right
rear side of vehicle. Turn adjusting wheel down on left side of vehicle. Turn both adjusting wheels until
rear brake disc can't be rotated (tight).
3. Turn adjusting wheels 8-9 teeth (down on right) and (up on left) until rear brake disc can be turned freely.
Turn adjusting wheel an equal number of turns at each wheel. Relieve load on automatic slack adjuster.
Using a screwdriver, lift up center spring clip. Automatic slack adjuster will automatically adjust. Firmly
operate parking brake several times. Parking brake should adequately apply in 10 or less notches.
Procedure D
1. Raise and support vehicle. Remove rear wheels. Preload automatic slack adjuster. See PRELOADING
AUTOMATIC PARKING BRAKE CABLE ADJUSTER .
2. Align wheel bolt hole with parking brake adjuster. Using a screwdriver, turn adjusting wheel from left to
right on both sides. Turn both adjusting wheels until rear brake disc can't be rotated (tight).
3. Turn adjusting wheels (approximately 5 teeth) from right to left on both sides until rear brake disc can be
turned freely. Turn adjusting wheel an equal number of turns at each wheel. Relieve load on automatic
slack adjuster. Using a screwdriver, lift up center spring clip. Automatic slack adjuster will automatically
adjust. Firmly operate parking brake several times. Parking brake should adequately apply in 10 or less
notches.
Remove rear seat cushion. Remove access panel under rear seat to access automatic cable length compensator.
Remove rear seat cushion and remove access panel. Using an Allen wrench, turn locking pin approximately one
turn clockwise. At the same time push locking pin back until spring-loaded locking eccentric ratchet locks into
place in spring clip. See Fig. 2 .
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Fig. 2: Identifying Automatic Parking Brake Cable Adjuster Components (C-Class, CLK & E-Class
Vehicles)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
On S-Class vehicles (1999) remove heat shield to access automatic cable length compensator. On all vehicles,
preload automatic slack adjuster. Using an Allen wrench, turn locking pin (in center) approximately one half
turn counterclockwise. At the same time push locking pin back until spring-loaded locking eccentric ratchet
locks into place in spring clip. See Fig. 3
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Fig. 3: Identifying Automatic Slack Adjuster Components (ML & S-Class Vehicles)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
WHEEL BEARINGS
NOTE: Front wheel bearing adjustment is not possible on E320 vehicles equipped with
4-Matic option or on ML320, ML430 and ML55.
CAUTION: Always use a dial indicator to ensure wheel bearings are properly
adjusted.
1. Raise and support vehicle. Remove front wheel and tire assembly. Remove brake caliper and wire aside.
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Install a wheel bolt opposite of rotor locking screw. Remove grease cap. Loosen bushing clamp hex head
pinch bolt. Install dial indicator on front hub. Loosen clamping nut until play can be detected. Tighten
clamping nut while simultaneously turning hub, until hub preload is .08" (2 mm). Zero dial indicator.
2. Check hub end play by pulling and pushing on hub flange. During measurement, wheel hub must not
turn. Loosen clamping nut until end play is .0004-.0008" (.01-.02 mm). Tighten hex head pinch bolt on
clamping nut to 71 INCH lbs. (8 N.m). Recheck end play.
TESTING
BRAKE FLUID LOSS
1. If brake fluid loss is not externally visible, remove brake master cylinder. See MASTER CYLINDER
under REMOVAL & INSTALLATION. Inspect brake booster for brake fluid. If brake fluid is not
present, inspect all system hydraulic connections and repair as necessary. If brake fluid is present, remove
brake fluid from brake booster and place into a measuring beaker.
2. If brake fluid volume is .11 qts. (.10L) or less, brake booster can be reused. The rolling diaphragm in
brake booster is resistant to brake fluid, but not the reaction disc and poppet valve in the control element.
When volume of brake fluid in brake booster is .11 qts. (.10L) or less, the brake fluid cannot reach the
reaction disc or poppet valve in an installed brake booster. If volume of brake fluid in brake booster is
more than .11 qts. (.10L), the brake booster is damaged must be replaced. See BRAKE BOOSTER
under REMOVAL & INSTALLATION.
NOTE: Model year 2000 S430 and S500 use electronic proportioning to control brake
pressure to rear brakes.
1. Turn ignition on. Dual warning light, mounted on dash, should glow when parking brake is applied one
notch and go off when parking brake is fully released.
2. To check circuit warning sensor, turn ignition on. Release parking brake and ensure light is off. Install
bleeder hose and open bleeder screw on one wheel. Slowly depress brake pedal, while catching brake
fluid in a container. Light should glow.
3. Close bleeder screw and release pedal. Bleed hydraulic system (if necessary). Ensure light goes out after
testing. If light does not go out, reset differential pressure pin in master cylinder.
CAUTION: Remove brake fluid as necessary to prevent brake fluid spillage when
pressing pistons back into caliper.
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1. Raise vehicle and support. Remove wheels. Disconnect brake pad wear sensor (if equipped). Using a
punch, remove retaining pins for brake pads. Remove spring clip. Remove brake pads. See Fig. 4 .
2. Replace brake pad wear sensor if insulation layer on contact plate is worn through or if sensor or wiring
are damaged. Before installing new pads, press pistons into caliper. If caliper has 4 pistons, wedge 2
pistons while pressing 2 remaining pistons back.
3. To complete installation, reverse removal procedure. Always install brake pad wear sensor on inner brake
pad. If caliper was removed, replace caliper retaining bolts. Ensure brake pad wear sensor wire is properly
routed. Before driving, pump brake pedal slowly until brake pads contact rotors.
1. Raise vehicle and support. Remove wheels. Remove cover for brake pad wear sensor connector.
Disconnect brake pad wear sensor connector (if equipped). DO NOT pull on sensor cable.
2. Remove guide bolt caps. Remove guide bolts. Remove brake pads with brake pad wear sensor. Secure
brake caliper with wire. Remove brake pad wear indicator sensor from brake pad.
3. To install, reverse removal procedure. See TORQUE SPECIFICATIONS . Always install brake pad
wear sensor on inner brake pad. Replace brake pad wear sensor if insulation layer on contact plate is worn
through or if sensor or wiring are damaged. Before installing new pads, press pistons into caliper. If
caliper has 4 pistons, wedge 2 pistons while pressing 2 remaining pistons back. Ensure brake pad wear
sensor wire is properly routed. Before driving, pump brake pedal slowly until brake pads contact rotors.
NOTE: Vehicles equipped with Acceleration Slip Regulation (ASR), Electronic Stability
Program (ESP) and/or Electronic Traction System (ETS) may have no brake pad
wear sensors, 2 brake pad wear sensors, or 4 brake pad wear sensors. Only
install number of sensors originally fitted in original location. Pay attention to
sensor wiring routing.
1. Raise vehicle and support. Remove wheels. Disconnect brake pad wear sensor (if equipped). Using a
punch, remove retaining pin(s) for brake pads. Remove spring clip. Remove brake pads. See Fig. 5 . To
install, reverse removal procedure.
2. Replace brake pad wear indicator sensor if insulation layer on contact plate is worn through or if sensor or
wiring are damaged. Before installing new pads, press pistons into caliper. If caliper has 4 pistons, wedge
2 pistons while pressing 2 remaining pistons back.
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2000 Mercedes-Benz SLK230
1999-2000 BRAKES Disc
Removal
Raise and support vehicle. Remove wheel and tire. Disconnect brake pad wear indicator sensor (if equipped).
Disconnect and plug brakelines at caliper assembly. Remove Speed sensor (if necessary). Remove caliper
attaching bolts. Remove caliper assembly from vehicle.
Installation
To install, reverse removal procedure. Replace self-locking caliper bolts. See TORQUE SPECIFICATIONS .
Bleed hydraulic brake system. See BLEEDING BRAKE SYSTEM . Ensure dash light goes out.
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Raise and support vehicle. Remove wheels. Remove caliper, and wire aside. Remove rotor-to-hub screw(s).
Remove rotor. To install, reverse removal procedure.
MASTER CYLINDER
CAUTION: DO NOT tilt master cylinder during removal. Pull straight out (forward). If
not pulled straight out, thrust rod will be pressed out of its axial position
and may break out of the retaining lugs.
NOTE: Master cylinder on 1999 CL500 and 1999 S500 is a switchable master cylinder
and is not repairable.
Removal
Drain master cylinder brake fluid. Disconnect and plug brakelines. Disconnect electrical connections. Remove
master cylinder-to-brake booster bolts. Remove master cylinder.
Installation
To install, reverse removal procedure. Always replace rubber "O" ring seal between master cylinder and brake
booster. On CL500 (1999), S320, S420 and S500 (1999) bleed master cylinder prior to installation, using bleed
screw on master cylinder. On all models, bleed hydraulic system and check complete system for fluid leaks. See
BLEEDING BRAKE SYSTEM . Ensure brake warning light is out.
CAUTION: If brake shoes are scorched, brake shoes and return springs must be
replaced. On vehicles with ventilated rear discs, brake discs must also be
replaced.
Removal
1. Raise and support vehicle. Remove rear wheel and tire. Remove caliper and rotor. Turn rear axle flange
until one threaded hole faces hold-down spring. Compress spring with Spring Installer/Remover (112 589
09 61 00) and turn 90 degrees.
2. Remove all retainers and hold-down springs. Detach lower return spring, opposite adjuster. Pull brake
shoes apart far enough to remove over rear axle shaft flange. Detach upper return spring. Remove
adjuster. See Fig. 6 .
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Installation
Return adjuster to home position. Install on shoes with adjuster facing forward. Attach hold-down springs,
retainers and return springs. Install rotor and adjust parking brake. See PARKING BRAKE under
ADJUSTMENTS.
BRAKE BOOSTER
Remove brake master cylinder. See MASTER CYLINDER under REMOVAL & INSTALLATION. With
vacuum hose connected to brake booster, pump brake pedal to release vacuum in brake booster. Disconnect
vacuum line at brake booster. Remove driver's side instrument panel under cover. Remove stop light switch.
Disconnect brake pedal return spring. Remove locking clip and remove clip retaining brake booster to brake
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pedal. Remove brake booster retaining nuts and remove brake booster. To install, reverse removal procedure.
Tighten nuts and bolts to specification. See TORQUE SPECIFICATIONS .
OVERHAUL
SERVICING PRECAUTIONS
Aluminum Pistons
Only use a soft cloth to service caliper piston and caliper bore.
Brake Calipers
If piston is stuck, scores are present, or rust is present in cylinder bore, replace complete caliper (fixed caliper)
or cylinder housing (floating caliper). Remove small rust points in cylinder bore with polishing cloth. If rust is
more severe in front of groove for piston seal, use a fine abrasive paper (380-500 grain).
Chrome Pistons
Only use a soft brass brush or a rough cleaning rag to clean chrome pistons. DO NOT use polishing or abrasive
cloths on pistons with chrome plating. If chrome plating is damaged, REPLACE piston.
On CL (2000), E-Class, ML and S-Class (2000) vehicles, DO NOT service 4-piston fixed calipers. Brake
calipers are not serviceable.
DO NOT use compressed air to remove fixed caliper pistons on front axles. Use Piston Turning Tongs (000 589
50 37 00).
Install piston into caliper bore so elevated section (marked Black) on piston points up when caliper is installed
on vehicle. Piston position can be checked with Inspection Gauge (000 589 50 37 00). This reduces the
tendency for brake squeak. If necessary, use Piston Turning Tongs (000 589 50 37 00) to align piston in caliper
bore. See Fig. 7 .
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Clean sliding pins and coat with special grease included in brake kit during assembly.
MASTER CYLINDER
NOTE: Master cylinder on 1999 CL500 and 1999 S500 is a switchable master cylinder
and is not repairable. Master cylinder overhaul information on other models is
not available.
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NOTE: Refer to illustration for master cylinder component identification. See Fig. 8 .
BRAKE BOOSTER
NOTE: Before servicing power brake unit, inspect check valve. Determine whether
problem is caused by power brake unit or check valve.
Manufacturer does not recommend disassembly. If problem is found in brake booster, replace complete
assembly.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
Brake Booster Mounting Nuts
C230, C280, C43, CLK320, CLK430, (1) CL500, E300 Turbo Diesel, E320, 15 (20)
E430, E55, S320, S420, (1) S500, SL500 & SLK230
CL500, S430 & (2) S500 18 (24)
ML320, ML430 & ML55 15 (20)
Brake Caliper Bleed Screw
ML320, ML430 & ML55 13 (18)
Brake Disc Locking Bolt
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