Changing the rear brake caliper repair kit on a Mercedes W124 involves disassembling and rebuilding the brake caliper. This process can be quite involved and requires careful attention to detail. Here are the general steps to guide you through the process:

Tools and Materials You May Need:

  • Rear brake caliper repair kit
  • Brake fluid
  • Brake cleaner
  • Brake piston tool (for compressing the piston)
  • Socket set
  • Wrenches
  • Screwdrivers
  • Rubber mallet
  • Brake bleeding kit
  • Safety equipment (gloves, safety glasses)

Procedure:

  1. Safety Precautions:
    • Ensure the vehicle is on a flat, stable surface, the engine is turned off, and the handbrake is engaged.
    • Wear safety gloves and glasses to protect your hands and eyes.
  2. Lift the Vehicle:
    • Lift the rear of the vehicle using a suitable jack and secure it with jack stands.
  3. Remove the Wheel:
    • Remove the rear wheel to access the brake caliper.
  4. Brake Fluid Reservoir:
    • Check the brake fluid reservoir and, if necessary, siphon off some brake fluid to prevent overflow when you compress the caliper piston.
  5. Disassemble the Brake Caliper:
    • Carefully remove the brake caliper from its mounting bracket.
    • Using the appropriate socket or wrench, disconnect the brake line from the caliper. Be prepared to catch any leaking brake fluid in a suitable container.
    • Disassemble the caliper by removing the retaining bolts, pins, and any other hardware that holds it together.
  6. Remove the Old Seals and Piston:
    • Carefully remove the old seals, o-rings, and piston from the caliper.
    • Inspect the caliper components for wear or damage.
  7. Clean the Caliper:
    • Thoroughly clean the caliper, including the caliper housing, piston bore, and all components. Use brake cleaner to remove any old brake fluid, dirt, and debris.
  8. Replace Seals and O-Rings:
    • Install the new seals and o-rings from the repair kit into the caliper.
    • Lubricate the new components with brake fluid before installation.
  9. Compress the Piston:
    • Use a brake piston tool or a suitable tool to compress the caliper piston back into its bore. Ensure it’s flush with the caliper housing.
  10. Reassemble the Caliper:
    • Reassemble the caliper, including all pins, bolts, and brackets, following the manufacturer’s instructions.
    • Reattach the brake line and ensure it’s properly tightened.
  11. Bleed the Brakes:
    • Bleed the brake system to remove any air. Starting with the furthest wheel from the master cylinder and working your way closer is a common method. Use a brake bleeding kit or ask someone to assist you.
  12. Refill Brake Fluid:
    • Top off the brake fluid reservoir with fresh brake fluid and replace the cap.
  13. Test the Brake Pedal:
    • Pump the brake pedal a few times to ensure the caliper piston seats properly.
    • Check for any brake fluid leaks around the caliper.
  14. Replace the Wheel:
    • Carefully reinstall the rear wheel and tighten the lug nuts.
  15. Lower the Vehicle:
    • Carefully lower the vehicle to the ground.
  16. Test the Brakes:
    • Test the brakes for proper operation by gently applying and releasing the pedal. Ensure there’s a firm brake pedal and that the vehicle stops correctly.

Rebuilding a rear brake caliper on a Mercedes W124 is a complex procedure that requires attention to detail and careful handling of brake components. If you’re not experienced with brake systems, it’s highly recommended to consult a professional mechanic or technician for assistance to ensure the job is done correctly and safely.