Remove/install front axle brake caliper

AR42.10-D-0070TS

Remove/install front axle brake caliper

08.06.2020

Model

907, 910

Modification notes

05.06.2020

Work procedure revised

The whole document

Shown on model 910

1

Brake caliper

4

Screw

6

Dust cap

2

Electrical wiring harness

5

Brake hose

7

Screw

3

Electrical wiring harness

 Danger

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

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

AS00.00-Z-0010-01A

 Danger

Risk of accident when commissioning the vehicle due to a lack of braking effect when the service brake is operated for the first time after repair work.

Before starting the engine, actuate brake pedal several times until pressure is built up and maintained in the brake system.

AS42.50-Z-0002-01A

 Warning

Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.

Wear protective gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

 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

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-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

Clean area surrounding cap of brake fluid reservoir.

Assembly cleaner

*BR00.45-Z-1028-04A

2

Remove cap from brake fluid reservoir.



Check

3

Check fill level in brake fluid reservoir.


The fill level must not be above the maximum marking.
This prevents the brake fluid reservoir from overflowing when the brake pistons are pushed back.

If the fill level in brake fluid reservoir is too high,



extract brake fluid.

 Commercially available devices/tools
Extraction bellows

4

Remove each front wheel.

AR40.10-D-1100TS

5

Disconnect electrical wiring harness (2) from electrical wiring harness (3) to electrical connector.

If installed on affected side of vehicle.

6

Remove electrical wiring harness (3) from brake caliper (1).

If installed on affected side of vehicle.

 To do this, remove bolt (4). Dispose of screw (4).

7

Remove brakepads on front axle.

AR42.10-D-1610TS

8

Remove brake hose (5).

AR42.10-D-0026TS

If cracks or chafe marks are present on brake hose (5),



replace brake hose (5).

9

Remove dust cap (6).

10

Remove brake caliper (1).

 Model 910
Remove bolt (7) to do this.
Dispose of bolt (7).

 Model 907
To do so, remove upper guide pin.

 When replacing the brake caliper (1), only install brake calipers (1) from the same manufacturer and model on an axle.



Check

11

Check condition of brake disk and gauge degree of wear.



AP42.10-D-4256TS

If the brake disk is outside the test tolerances,



Replace brake disks in sets.

AR42.10-D-0230TS

12

Check existing version of brake caliper support.

When replacing the brake caliper (1) together with the brake caliper guide or when replacing the brake caliper guide.



Front axle brake caliper support modified

BT42.10-D-0222-01TS

 Observe notes on modified version of brake caliper support.

13

Check brake caliper (1) and dust boot on each brake piston for leak tightness and damage.

If a leak or damage is present,



Replace brake caliper (1).

14

Check boots and brake caliper support for damage and ease of movement.

If damage or sluggishness is present,



replace affected components.



Clean

15

Clean thread of upper guide pin.

Model 907

Assembly cleaner

*BR00.45-Z-1028-04A

16

Check upper guide pin for damage.

Model 907

If damage is present,



replace upper guide pin.



Install

17

Install brake caliper (1).

 Model 910
To do so, screw in new bolt (7).

 Model 907
To do so, screw in upper guide pin.

 Screw/guide pin, brake caliper to brake caliper support

*BA42.10-N-1004-10TS

18

Install dust cap (6).

19

Install brake hose (5).

AR42.10-D-0026TS

 Do not yet bleed brake system.

20

Install front axle brakepads.

AR42.10-D-1610TS

 Do not operate brake pedal yet.

21

Attach electrical wiring harness (3) to brake caliper (1).

If installed on affected side of vehicle.

 To do so, screw in new bolt (4).

 Bolt, wiring harness for wear indicator to brake caliper

*BA42.10-N-1003-10TS

22

Connect electrical wiring harness (2) with electrical wiring harness (3) to electrical connector.

If installed on affected side of vehicle.

23

Mount respective front wheel.

AR40.10-D-1100TS

24

Bleed brake system.

AR42.10-D-0010TS



Check

25

Perform brake test on test stand.



AP42.00-D-4290TS

 Front axle brake caliper

Number

Designation

Model 907

Model 910

BA42.10-N-1003-10TS

Bolt, wiring harness for wear indicator to brake caliper

Nm

8

8

 Front axle brake caliper

Number

Designation

Model 907

Model 910

BA42.10-N-1004-10TS

Screw/guide pin, brake caliper to brake caliper support

Nm

34

34

Repair materials

Number

Designation

Order number

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01