Remove/install front axle brake caliper

AR42.10-D-0070E

Remove/install front axle brake caliper

20.04.2017

Model

904

Brake caliper upper section on Wabco-Perrot brake caliper

Modification notes

10.04.2017

Basic data value for brake hose threaded connection to brake caliper added

Operation step 9

10.04.2017

Special tool 129 589 00 91 00 Set of stop plugs added

Step 5

10.04.2017

Document structure and work procedure revised

Operation steps 1 to 16

1

Pilot bushing

3

Screw

4

Wear indicator cable

5

Screw

6

Brake hose

7

Brake line

9

Wear indicator

10

Top section of brake caliper

1

Guide sleeves

 Caution

Risk of poisoning from swallowing brake fluid. Risk of injury from skin and eye contact with brake fluid

Only pour brake fluid into suitable and appropriately marked containers. Wear protective clothing and eye protection when handling brake fluid.

AS42.50-Z-0001-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Topical note

Notes on repairs to brake system

AH42.00-P-0003-01A

Topical note

Brake fluid notes

AH42.50-P-0001-01A

Topical note

Notes on bleeding brake system

AH42.10-N-0002-01A



Remove

1

Unscrew cap from brake fluid reservoir

2

Remove each front wheel

AR40.10-D-1100A

3

Remove bolt (3)

 The screw (3) is no longer required.

4

Detach wear indicator cable (4) from wear indicator (9)

5

Remove brake hose (6)


Seal off brake line (7) and connecting thread on brake caliper upper section (10) using one stop plug each.
Otherwise the brake system may fail due to contamination.

 Box wrench bit

*000589750300

 Record plug

*129589009100

6

Remove brake caliper upper section (10)

 To do this, remove the bolts (5).



Install

7

Remove residues of self-locking coating from pilot bushings (1) using M8 thread tap

8

Push back brake pistons

AR42.10-D-1600-09A

 Resetting device

*000589524300

9

Install brake hose (6) on brake caliper upper section (10)

 Threaded connection, brake hose to brake caliper

*BA42.10-N-1004-04A

 Box wrench bit

*000589750300

10

Install brake caliper upper section (10)

 Replace screw/bolts (5).

 Model 904 with front axle 730.4Guide pin/catch bolt, top section of brake caliper to brake caliper support

*BA42.10-N-1004-10A

11

Attach brake hose (6) to brake line (7)


Do not install the brake hose (6) twisted and make sure that it can move freely.
Otherwise damage may occur.

 Threaded connection, brake line to brake hose

*BA42.10-N-1001-04A

 Box wrench bit

*000589750300

12

Attach wear indicator cable (4) to wear indicator (9)

13

Screw in new screw (3)

 Model 904 with front axle 730.4Bolt, wear indicator to brake caliper

*BA42.10-N-1003-10A

14

Bleed brake system

AR42.10-D-0010A

15

Screw cap onto brake fluid reservoir

16

Mount relevant front wheel

AR40.10-D-1100A

 Brake hoses, brake lines

Number

Designation

Model 690.6, 901, 902, 903, 904 without code BB0 (ABS/ABD)

Model 690.6, 901, 902, 903, 904 with code BB0 (ABS/ABD)

BA42.10-N-1001-04A

Threaded connection, brake line to brake hose

M101

Nm

14

14

 Front axle brake caliper

Number

Designation

Model 904

BA42.10-N-1003-10A

Bolt, wear indicator to brake caliper

M6

Nm

10

 Brake hoses, brake lines

Number

Designation

Model 690.6, 901, 902, 903, 904 without code BB0 (ABS/ABD)

Model 690.6, 901, 902, 903, 904 with code BB0 (ABS/ABD)

BA42.10-N-1004-04A

Threaded connection, brake hose to brake caliper

Nm

24

24

 Front axle brake caliper

Number

Designation

Model 904

BA42.10-N-1004-10A

Guide pin/catch bolt, top section of brake caliper to brake caliper support

M8

Nm

25

M10/10.9

Nm

30