Remove/install rear-axle brake caliper

AR42.10-D-0080H

Remove/install rear-axle brake caliper

17.03.2017

Model

903.61/62/66/67 with rear axle 741.408

with code ZU9 (National version for Mexico)

Model

903.61/66/67 with rear axle 741.408 #L as of 902370

with code ZU8 (National version for USA)

Model

903.61/66/67 with rear axle 741.408 #X as of 322253

with code ZU8 (National version for USA)

Model

903.61/66/67 with rear axle 741.408 #Z as of 172162

with code ZU8 (National version for USA)

Model

903.61/66/67 with rear axle 741.408

with code ZU7 (National version for Canada)

Modification notes

15.03.2017

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

Operation step 4

15.03.2017

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

Operation step 4

1

Screw

2

Wear indicator

3

Brake hose

4

Bolts

5

Brake caliper

6

Wear indicator cable

 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 bleeding brake system

AH42.10-N-0002-01A

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

 

Remove/install

1

Unscrew cap from brake fluid reservoir

2

Remove relative rear wheel

AR40.10-D-1100A

3

Remove wear indicator (2) and wear indicator cable (6)

 To do this, remove screw/bolt (1).

 Installation: Replace screw/bolt (1).

 Bolt, wear indicator to brake caliper

*BA42.10-N-1004-12A

4

Unscrew brake hose (3) at vehicle end and at brake caliper (5)


Seal line end and connection thread on brake caliper (5) with stop plug each.
Otherwise the brake system may fail due to contamination.

 Installation:
Do not install the brake hose (3) twisted and make sure that it can move freely.
Otherwise damage may occur.

 Installation: Check brake hose (3) for cracks.

 Model 903.6 with code BB0 (Brake system, ABS anti-lock braking system) model 903.6 except code BB0 (Brake system ABS anti-lock braking system)Threaded connection, brake line to brake hose

*BA42.10-N-1001-04A

 Model 903.6 with code BB0 (Brake system, ABS anti-lock braking system) model 903.6 except code BB0 (Brake system ABS anti-lock braking system)Threaded connection, brake hose to brake caliper

*BA42.10-N-1004-04A

 Record plug

*129589009100

 Box wrench bit

*000589750300

With tears on brake hose (3)



Replace brake hose (3).

5

Remove brake caliper (5)

 For this purpose, remove bolts (4).

 When replacing the brake caliper (5), only brake calipers (5) from the same manufacturer may be installed on the same axle.

 Installation: Replace screws/bolts (4).

 Bolt, brake caliper support to rear axle tube

*BA42.10-N-1001-12A

6

Install in the reverse order

7

Bleed brake system

AR42.10-D-0010B

 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

 Rear axle brake caliper

Number

Designation

Model 903

BA42.10-N-1001-12A

Bolt, brake caliper support to rear axle tube

M121.5

Nm

105

M141.5

Stage 1

Nm

-

Stage 2

°

-

M161.5

Stage 1

Nm

-

Stage 2

°

-

 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

 Rear axle brake caliper

Number

Designation

Model 903

BA42.10-N-1004-12A

Bolt, wear indicator to brake caliper

M6

Nm

10