Remove/install front axle brake caliper

AR42.10-P-0070EM

Remove/install front axle brake caliper

19.11.09

 

Remove/install

 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

1

Remove front wheels



AP40.10-P-4050Z

2

First disconnect brake hose (51) at brake line (5) and then at fixed caliper (31)

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



Notes on installing brake hoses

AH42.10-P-9406-01A



Brake hose connection to brake line modified

Model 202, 210 as of 09.95

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

Unplug brake pad wear sensor (S10/1) from connector (57).

 Contact sensor for front axle

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

Location of wear sensor on:

Lucas fixed brake caliper: On external brake pad.



Notes on installing brake pad wear sensor contact sensors

AH42.10-P-0003-01A

4

Unscrew connector (57)

Model 202:

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

*BA42.10-P-1004-10K

Model 210:

 Bolt, brake pad contact sensor to brake caliper

*BA42.10-P-1004-10F

5

Remove speed sensor (L6/1)

 Self-locking bolt, front axle rpm sensor to steering knuckle

*BA42.30-P-1001-01A

6

Unbolt fixed caliper (31) from steering knuckle

 Installation: Replace self-locking bolts (35).

Model 202:

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

*BA42.10-P-1001-10K

Model 210:

 Self-locking bolt, brake caliper to steering knuckle

*BA42.10-P-1001-10F

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
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
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
202

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

Number

Designation

Model 202

Model 210

BA42.30-P-1001-01A

Self-locking bolt, front axle rpm sensor to steering knuckle

Nm

22

22