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Old 09-21-2016, 07:18 PM
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Join Date: Apr 2012
Posts: 464
1994 E320 wagon driver side caliper top bolt stuck issue

I am trying to remove the caliper on my 1994 E320 wagon driver side. There are two bolts holding the caliper to the rotor. I was abled to removed the bottom caliper bolt using 3/4 inch six point socket and breaker bar with little difficulty due to more leverage and more space to work with. When I removed the bolt, I notice blue coloring on the end of bolt thread about 1/4 inch long. it must be locite for tightening bolt threads. When trying to remove the top bolt on the caliper, this is were I am having some problems. Using the same setup as above 3/4 inch six point socket and breaker bar, the caliper top bolt won't move. I had just finished replacing all the other three rotors and brake pads on the other three wheels myself and now come to only one bolt left to remove. I tried using PB Blaster on the bolt. I even tried to push the breaker bar using both feet standing up going down, even the wheel was turned all the way to the right so I have some more room and leverage to work with, barely. That is one tough bolt and still won't bulge. The driver's side front wheel is on one jack stand leaving very little leverage and room to work with from the bottom of the asphalt floor. I tried smaller ratchets and going under the wheel and still no luck. The breaker bar is too long to manuever any leverage left I have while trying to remove the bolt inside and under the wheel with limited space. It seems I need more space and leverage to remove the only bolt left. It sure baffles me, because I was able to do the other three calipers with little difficultly in removing caliper bolts. Also, there is very little space between the bolt on the caliper and wheel joint (if that is what is called), because using the socket and adapter and breaker bar takes up some room with limited space to manuever when trying to remove the bolt.
I read some articles about removing caliper bolts and it seems that using a propane torch or some other stuff to produce heat on the darn bolt head and hopefully ease up the threads to make it easy to remove the bolt . I am very hesitate using the propane blow torch because I never use one before and concerns about getting some other areas around the brake system on fire by accident due to limited leverage and space around the caliper.

It seems to me the best and safest option is put back together the old brake pads, rotor, and drive the mercedes wagon to the shop. The mechanic in the shop will be using the vehicle lift and whatever tools necessary to remove that stuck bolt and then replacing old brake pads and the rotor with new pads and rotor.(my replacements parts I bought rotor and brake pads) The mechanic is just doing the labor and nothing else. I feel by going this route will cost me extra bucks when I could have done this myself and defeat the purpose of do it youself. Any comments and/or feedback is greatly appreciated.
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