c240classic

Tried penetrating oil and a drift punch with big hammer. There is no give! Is drilling my only option? I can drill the front while it is still on the car but to drill the back I need to take caliper off! What can I plug the brake line with as I do this ?
Any other tips? I don't have a press so I will be hand drilling.

sammydragon3

i had to do this on the front the pin was stuck...only way to get out was to drill it with a hand drill with the caliper on the car

drill away!!!

c240classic

What a poor design!! so you drilled it all the way through the front?. the reason y i ask is because the pin is tapered. So if i put the drill on the outside i only have access to the small end of the pin. once i drill that completely, the big end is on the back side and if i try to drill straight from one of the pin to the other, i will enlarge the small hole and the new pin will not seat in. any tips ?

ontmiss

Here is 1, will not hurt to try.
I found out that wire from dry cleanning hanger has right diameter for that hole, maybe a bit soft but few tries could do the trick. I did it on first try, probably because wasn't stuck as bad. If you find some more solid wire even better.
Here is how was done.
Put wire inside a hole and cut it 5 mm to stick out.
Remove piece and sand it flat on both sides so after that sticks out 3-4 mm.
Put it back and, find hammer with both flat end (or something similar), hold it on wire end and hit very hard that hammer (or SS) with another one (hammer)

Good Luck!

slammer111

Can someone take a photo? Which pin are we talking about? The only pin I know on the W203 are in the rear, and they can be pounded out with a screwdriver?

Boom vang

with the sports package the sedan has fixed calipers either 4 pots (2004 and earlier and C32/55) or two piston (2005 to 2007) made by Brembo on the front which also has pins securing the pads. The coupe and non sports versions have a single piston sliding caliper made by Lucas

c240classic

yes, usually that pin can be pounded out with a screw driver. However when it seizes because of salt on the road exposure over time, it is a pain to take out.
I doubt the coat hanger trick will work because i have a drift punch that fits in well and pounded on it with a big hammer and bent the punch. I am afraid of heating it and ruining the seals on the caliper!
I had to put everything back temporarily so that i can pick up spare pins on monday and then try drilling this stupid pin out.
The pin is so exposed, wherever they put salt on the road, it will seize right up. Anybody ever tried heating it or will i ruin the caliper ?

sammydragon3

just drill out the small end which faces u out....this is the only thing u can do...or u can buy another caliper for 200

u only have to drill a little bit of the pin...until u can smash it out with the drive pin

c240classic

so you are saying to drill out the small end, cut the inner end of the bigger pin, put a bigger punch on it and go at it ?

Boom vang

get a small metal brush and aggressively brush all around the pin and opening, spray some PB Blaster the night before. Get a quality and correct size punch and hit it with a BFH or deadblow hammer, it will come out, they are seized but not welded together

RacingBrake

We have just release this handy tool to make your brake pad replacement easier:

http://forums.racingbrake.com/showthread.php?t=1390