with a new front rotor and new brake pads, i can't get the caliper to fit over it.

so I resorted to putting 1 old pad back (the thicker one) until the new one wears out a little more then I will put the other new pad on.

is there a way to shave a brake pad a little without ruining it?

__________________
Ben
1987 190d 2.5Turbo

Are you sure you compressed the pistons on the caliper fully?

__________________
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Ben, normally you would replace the rotor then reinstall the brake caliper without the new brake pads in place. Then depress the caliper pistons and install the new brake pads. I own two 1995 E320's and never had any problem installing new brake pads after replacing the front rotors. Having said that, I purchase new rotors from our local MB dealer and buy Textar brake pads online. Perhaps the new parts you're using caused the fit problem.

__________________
Fred Hoelzle

Ah after re-reading the post, it sounds like the pistons were not compressed back fully.

__________________
Cruise Control not working? Send me PM or email (jamesdean59@gmail.com). I might be able to help out.
Check here for compatibility, diagnostics, and availability!

(4/11/2020: Hi Everyone! I am still taking orders and replying to emails/PMs/etc, I appreciate your patience in these crazy times. Stay safe and healthy!)


82 300SD 145k
89 420SEL 210k
89 560SEL 118k
90 300SE 262k RIP 5/25/2010
90 560SEL 154k
91 300D 2.5 Turbo. 241k
93 190E 3.0 235k
93 300E 195k

To expand on jd's post, it sounds like: Both pads were removed, piston A pushed back, piston B pushed back but A crept forward.

The solution is to push one piston back, insert pad, push the other back, insert pad and pins.

Sometimes the sides of the pad have burs that need cleaned off so use a file to take the high spots off. If you really do need to thin the friction material, 40 grit sand paper works just fine on a flat surface

I had the same problem when I changed the pads of my E320 (curiously, I never had that problem with any other car). It turns out the slots in the caliper needed a good cleaning with a screwdriver and wire brush. The slots are where the brake pad backing plate mounts into. A good cleaning allowed the pads to seat properly.