I have a 2002 S430. At 25000 miles I needed all new pads and rotors (rotors rusted). At 45000 miles I need them all replaced again (rotors again rusted). Most all mileage was highway miles. To top this off a "new" special tool is needed to do work so only Mercedes garage can do it. Anyone out there know what my brake problem is - is it auto design flaw? Thanks

Firstly, did a mechanic/shop tell you the brakes were worn or did you work it out/light came on?

Secondly were the rotors actually warped or undersize? a little surface rust near the hub is normal.

Thirdly, I'd love to know what this special tool is for the brakes.........The only vehicle that needs more than a pin punch, spanner, torx or hex socket is a SBC equiped vehicle (which yours isn't) and thats just to disable the braking system electrically.

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Alex.

MB Tech
Sydney, Australia
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I agree, I wouldn't be replacing brakes because the rotors are rusty, unless it's to the point that the rotors are badly pitted with rust or the wheels won't even turn. What was the complaint that lead to the service visit? Did you complain about squeeling brakes and that's why they replaced parts?
On this car, I also have no idea what special tool would be required to work on these brakes.
If the car is driven regularly, rust shouldn't be a problem, unless the storage area is very humid, such as underground parking or a dirt floor garage.
Gilly

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My car never squeeled when brakes applied - rather it was a shutter - both times. Once at 45000 mukes and once at 25000. All highway miles and I park in enclosed garage. Both times rotors warped and rusted? Could it be a design problem??

I will find out this special tool today and post it. THanks RUdy

Have you had another shop rotate the tires? They could have torqued the lugs with an air wrench, causing warped rotors.

Do you wash the wheels when they are hot? Cold water on hot rotors can cause this too if I am correct

Cast iron rusts, there will be surface rust on even new rotors after a few days. Now, if the rotors are severely warped and causing the shddering, then they should be replaced. Above poster made a good point about a primary cause of rotor warping, putting the lug bolts on too tight. Is anything actually worn, or is the complaint just shuddering upon braking?

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Ali Al-Chalabi

2001 CLK55
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