Remove/install brake lines

AR42.10-D-0020A

Remove/install brake lines

09.03.2020

Model

667, 668, 670, 690.6, 900, 901, 902, 903, 904, 905, 906, 909

1

Flange bolt

2

Brake line

a

F-flange (115°)

d

Line diameter Ø 4.75 mm

d2

Flange diameter (Ø = 7.1  0.18 mm)

X

Flange height (height = 2.3  0.3 mm)

 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

Brake fluid notes

AH42.50-P-0001-01A

Topical note

Notes on repairs to brake system

AH42.00-P-0003-01A



Remove

1

Define length of new brake line (2) to match the old brake line (2)

With partial replacement of brake line (2).

 Two additional separating points per brake line (2) are permissible. With partial replacement of a brake line (2), use only partial replacement with brake lines (2) with line diameter Ø 4.75 mm (d) (wheel line).

 Select separating points at an easily accessible point. If this is not possible, remove the complete brake line (2).

 The separating points must be in perfect condition.

 Heater lines (master brake cylinder to hydraulic unit), plastic-coated lines and lines with flexible part are excluded from the repair.

2

Thoroughly clean repair area on brake line (2) and area immediately surrounding vehicle

Assembly cleaner

*BR00.45-Z-1028-04A

3.1

Remove brake line (2)

For replacement of complete brake line (2).

3.2

Cut brake line (2) using pipe cutter

With partial replacement of brake line (2).



Install

4

Make flange on brake line (2)

 Installation: Use specified line connectors only.

 Before making the flange, fit the flange bolt (1) on the respective brake line (2).

 For Mercedes-Benz VANS only brake lines (2) with an F-flange (a) as per DIN 74234 are used.

 When making a flange for the brake line (2), the tool manufacturer specifications must be complied with.

5

Adapt new brake line (2)


When routing the brake line (2) make sure there is sufficient distance to other components.
Otherwise, there may be kinking and line narrowing on the brake line (2).

 Adapt brake line (2) using bending tool to old configuration.
A bending radius of 13 mm must not be dropped below.

 Pipe bending tool

*000589393100

6

Install new brake line (2)

 Install brake line (2) free of tension and with correct torque on threaded connection.

 Model 690.6, 901, 902, 903, 904
except code BB0 (Antilock brake system (ABS))
Model 690.6, 901, 902, 903, 904
with code BB0 (Antilock brake system (ABS))
Model 900
Model 905
Model 906
Model 909Threaded connection, brake line to brake hose

*BA42.10-N-1001-04A

 Model 667
Model 668, 670Bolted connection of brake line

*BA42.10-N-1001-04C

 Model 667
Model 668, 670
Model 690.6, 901.6, 902.6, 903.6, 904.6, 905.6
with code BB0 (Antilock brake system (ABS))
with ABS/ABD
Model 900
Model 901.0/3/4, 902.0/3/4, 903.0/3/4, 904.0/3/4
with code BB0 (Antilock brake system (ABS))
with ABS/ABD
Model 906
Model 909Threaded connection for brake lines at hydraulic unit

*BA42.30-N-1003-03A



Check

7

Check surface of brake line (2) for paint damage and use textured paint to repair any damage, if necessary

Textured paint (color number A2)

*BR00.45-Z-1023-07A

8

Thoroughly wax the brake line (2) after mounting it

Cavity preservation (free of solvents), 1 liter

*BR00.45-Z-1011-05A

9

Bleed brake system

Model 690.6, 901, 902, 903, 904, 905

AR42.10-D-0010A

Model 900, 906

AR42.10-D-0010H

Model 667
Model 668, 670
except code B16 (Brake hydraulic 2-circuits/compr.-air 2-circuits)

AR42.10-L-0010A

Model 668, 670
with code B16 (Brake hydraulic 2-circuits/compr.-air 2-circuits)

AR42.10-L-0010B

10

Check brake system for leaks

AR42.10-S-0100-01S

11

Brake testing on test stand



Model 909

AP42.00-D-4290R



Model 690.6
Model 900, 906
Model 901, 902, 903, 904, 905

AP42.00-D-4290A

 Brake hoses, brake lines

Number

Designation

Model 909

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

BA42.10-N-1001-04A

Threaded connection, brake line to brake hose

M101

Nm

14

14

 Brake hoses, brake lines

Number

Designation

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

Model 905

BA42.10-N-1001-04A

Threaded connection, brake line to brake hose

M101

Nm

14

14

 Brake hoses, brake lines

Number

Designation

Bolt 900

Model 906

BA42.10-N-1001-04A

Threaded connection, brake line to brake hose

M101

Nm

14

14

 Brake lines, brake hoses

Number

Designation

Model 667

Model 668, 670

BA42.10-N-1001-04C

Bolted connection of brake line

Nm

16

16

 Hydraulic unit

Number

Designation

Model 909

Model 667

BA42.30-N-1003-03A

Threaded connection for brake lines at hydraulic unit

M101

Nm

–

16

M121

Nm

14

16

 Hydraulic unit

Number

Designation

Model 668, 670

Model 690.6, 901.6, 902.6, 903.6, 904.6, 905.6
with code BB0 (Antilock brake system (ABS))
with ABS/ABD

BA42.30-N-1003-03A

Threaded connection for brake lines at hydraulic unit

M101

Nm

16

16

M121

Nm

16

–

 Hydraulic unit

Number

Designation

Model 901.0/3/4, 902.0/3/4, 903.0/3/4, 904.0/3/4
with code BB0 (Antilock brake system (ABS))
with ABS/ABD

Model 900

BA42.30-N-1003-03A

Threaded connection for brake lines at hydraulic unit

M101

Nm

16

–

M121

Nm

–

14

 Hydraulic unit

Number

Designation

Model 906

BA42.30-N-1003-03A

Threaded connection for brake lines at hydraulic unit

M101

Nm

–

M121

Nm

14

Repair materials

Number

Designation

Order number

BR00.45-Z-1011-05A

Cavity preservation (free of solvents), 1 liter

A 000 986 72 70 10

BR00.45-Z-1023-07A

Textured paint (color number A2)

A 001 986 79 36

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01