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TXBill,
I have done the job without jack stands too, but not on a W126. I did it on my 1975 and 1982 240D's with similar precautions as you cited. Also, I took extra care to keep major body parts out from under the car when I was working. But jack stands make it a lot less scary.
I have always encountered the cover and cotter pins on W123's but can't say I remember what is on the W126 or W201 calipers. I think you are right about the cotter pins. Some cars just have a really tight fit on the retaining pins in the last few mm of travel.
adaiw83,
The wear pad sensors sometimes require a new lead as, if you let pad wear down with the dash light on you can grind away the sensor. I typically change them before they get damaged (they typically light up the dash light when the brake pad material is still there, but thin around the sensor wire, in wet weather) so I don't have to buy new ones. Genuine MB pads come with the features to plug the sensor lines into.
Good luck, Jim
__________________
Own:
1986 Euro 190E 2.3-16 (291,000 miles),
1998 E300D TurboDiesel, 231,000 miles -purchased with 45,000,
1988 300E 5-speed 252,000 miles,
1983 240D 4-speed, purchased w/136,000, now with 222,000 miles.
2009 ML320CDI Bluetec, 89,000 miles
Owned:
1971 220D (250,000 miles plus, sold to father-in-law),
1975 240D (245,000 miles - died of body rot),
1991 350SD (176,560 miles, weakest Benz I have owned),
1999 C230 Sport (45,400 miles),
1982 240D (321,000 miles, put to sleep)
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