Remove/install front axle brake caliper

AR42.10-P-0070BM

Remove/install front axle brake caliper

19.11.09

 

Remove/install

 Danger!

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer.

AS00.00-Z-0010-01A

 Danger!

Risk of poisoning caused by swallowing brake fluid. Risk of injury caused by brake fluid coming into contact with skin and eyes.

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



Brake fluid notes

AH42.50-P-0001-01A



Notes on repairs to brake system

AH42.00-P-0003-01A



Notes on installing brake hoses

AH42.10-P-9406-01A

1

Remove front wheels



AP40.10-P-4050Z

2

Disconnect brake hose (51) at the brake line (5) first and then at the floating brake caliper (31a)

 Plug connections immediately. Brake fluid reservoir must not empty completely.



Brake hose connection to brake line modified

Model 202, 210 as of 09.95

 Both versions are not interchangeable.

BT42.10-P-0001-01A

 Brake line to brake hose

*BA42.10-P-1001-04A

 Brake hose to fixed or floating caliper

*BA42.10-P-1002-04A

 Box wrench

*000589750300

 Box wrench

*000589760300

3

Detach contact sensor (S10/1) at brake pad contact sensor connector (S10/1x1)

 Corresponding to the number of plug contacts, install one or two contact sensors per wheel side

Location of wear sensor on:

Lucas floating brake caliper: on outer brake pad.

Teves floating brake caliper: on inner brake pad.

A contact sensor is installed on model 202   and Taxi version as of 09.95.



Notes on installing brake pad wear sensor contact sensors

AH42.10-P-0003-01A

4

Unscrew brake pad contact sensor connector (S10/1x1) from floating brake caliper (31a)

 Installation: Replace microencapsulated bolt (31e).

Model 170:

 Self-locking bolt, brake pad contact sensor to brake caliper

*BA42.10-P-1004-10P

Model 202:

 Self-locking bolt, brake pad contact sensor to brake caliper

*BA42.10-P-1004-10K

Model 208:

 Bolt, brake pad contact sensor to brake caliper

*BA42.10-P-1004-10D

Model 210:

 Bolt, brake pad contact sensor to brake caliper

*BA42.10-P-1004-10F

5

Unscrew bolts (35)

 Installation: Replace self-locking bolt.

Model 170:

 Self-locking bolts, brake caliper support to steering knuckle.

*BA42.10-P-1001-10P

Model 202:

 Self-locking bolts, brake caliper support to steering knuckle.

*BA42.10-P-1001-10K

Model 208:

 Self-locking bolt, brake caliper to steering knuckle

*BA42.10-P-1001-10D

Model 210:

 Self-locking bolt, brake caliper to steering knuckle

*BA42.10-P-1001-10F

6

Remove floating brake caliper (31a) together with the brake caliper support

7

Install in the reverse order

8

Bleed brake system

AR42.10-P-0010A

9

Check brake system for leaks

AR42.10-P-0100-01A

Number

Designation

Model
170

BA42.10-P-1001-10P

Self-locking bolt, caliper support to steering knuckle

Nm

115

BA42.10-P-1004-10P

Self-locking bolt, brake pad contact sensor to brake caliper

Nm

7

Number

Designation

Model
202.018/020/
022/023/033/
078/080/081/
083/087/093/
120/121/122/
125/133/134/
180/182/193/
194,
Model
202.028
up to 08/95

Model
202.024/025/
026/029/082/
085/086/088/
089/128/188,
Model
202.028
as of 09/95

BA42.10-P-1001-10K

Self-locking bolt, caliper support to steering knuckle

Nm

115

115

BA42.10-P-1004-10K

Self-locking bolt, brake pad contact sensor to brake caliper

M6

Nm

-

-

M8

Nm

22

22

Number

Designation

Model
208

BA42.10-P-1001-10D

Self-locking bolt, brake caliper to steering knuckle

Nm

115

BA42.10-P-1004-10D

Bolt, brake pad contact sensor to brake caliper

M6

Nm

-

M8

Nm

22

Number

Designation

Model
210

BA42.10-P-1001-10F

Self-locking bolt, brake caliper to steering knuckle

Nm

115

BA42.10-P-1004-10F

Bolt, brake pad contact sensor to brake caliper

M6

Nm

-

M8

Nm

22

Number

Designation

Model
170

Model
202

BA42.10-P-1001-04A

Brake pipe to brake hose

Nm

14

14

BA42.10-P-1002-04A

Brake hose to fixed or floating caliper

Nm

18

18

Number

Designation

Model
208

Model
210

BA42.10-P-1001-04A

Brake pipe to brake hose

Nm

14

14

BA42.10-P-1002-04A

Brake hose to fixed or floating caliper

Nm

18

18