Remove/install front axle brake disk

AR42.10-D-0230H

Remove/install front axle brake disk

25.06.2020

Model

900, 906

Modification notes

24.06.2020

Work procedure revised

The whole document

Model 900.63, model 906.11/13/21/23/61/63/71/73, shown on model 906.633

1

Brake carrier

3

Locking bolt

4

Brake disk

2

Bolts

Model 900.65, model 906.15/25/65, shown on model 906.653

1

Brake carrier

2

Bolts

4

Brake disk

5

Wheel flange

 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. Moving parts can pinch, crush or, in extreme cases even sever extremities.

No parts of the body or limbs should be within the operating area of mechanical components when moving components.

AS00.00-Z-0009-01A

 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

 Caution

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A

Topical note

Notes on evaluating brake disks

AH42.10-N-9406-07B

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

Remove brake pads.

AR42.10-D-1600H

 Installation: Check brakepads for damage.

If damage is present,



Replace brakepads as a complete set.

2

Remove brake carrier (1).

Topical note

Notes on threaded connections fastened using a tightening angle-based tightening process

AH00.00-P-0020-01A

 Remove brake carrier (1) with brake caliper and tie up.

 Installation: Replace screw/bolts (2).

 Bolt securing brake caliper

*BA42.10-N-1001-10H

3.1

Remove safety screw (3) of brake disk (4).

Model 900.63
Model 906.11/13/21/61/63/71/73

 To do so, screw in two wheel studs and counterhold the brake disk (4) using a suitable tool. Then remove the wheel stud.

 Model 900.63
Model 906.11/13/21/23/61/63/71/73Brake disk bolt

*BA42.10-N-1001-11A

3.2

Remove wheel flange (5).

Model 900.65
Model 906.15/25/65

 Position suitable tool between the two wheel studs for counterholding.

 Installation: Clean all contact surfaces.
Replace screw securing wheel flange to wheel hub.

Assembly cleaner

*BR00.45-Z-1028-04A

 Model 900.65
Model 906.15/25/65Bolt, wheel flange to wheel hub

*BA33.20-N-1004-01N

4

Remove brake disk (4).

 Installation: Clean all contact surfaces.
Apply light coating of grease to contact surface for centering brake disk (4) on wheel hub.

Assembly cleaner

*BR00.45-Z-1028-04A

Long-life grease

*BR00.45-Z-1001-06A



Check

5

Check brake disk (4) for damage and wear.



Assess condition of brake disks

AP42.10-D-4256H

 Installation: If the brake disks (4) are to be replaced, the brakepads must also be replaced as a complete set.

Brake disk

*BE42.10-N-1001-08B

 Caliper gauge

*140589001900

6

Install in the reverse order.

7

Build up brake pressure by fully depressing brake pedal several times.



Check

8

Check fluid level in brake fluid reservoir.



Hydraulic brake system - check fluid level, correct if necessary

AP42.50-D-4210H

If fluid level is not correct,



correct fluid level.



Brake fluids (DOT 4 plus)

BB00.40-P-0331-00A

 Commercially available devices/tools
Extraction bellows

9

Check brake system for leaks.

AR42.10-S-0100-01S

10

Perform brake test.



Brake test

AP42.00-D-4290A

Check values for front axle brake disks

Number

Designation

Model 900

Model 906

BE42.10-N-1001-08B

Brake disk

Thickness when new

mm

28

28

Wear limit

mm

25

25

Lateral runout

mm

 0,03

 0,03

Flatness deviation

mm

 0,04

 0,04

Repair limit dimension

mm

-

-

 Wheel control, hub

Number

Designation

Model 900

Model 906.15/25/65

BA33.20-N-1004-01N

Bolt, wheel flange to wheel hub

M14x1.5

Nm

170

170

 Front axle brake caliper

Number

Designation

Model 900

Model 906

BA42.10-N-1001-10H

Bolt securing brake caliper

M141.5

Stage 1

Nm

80

80

Stage 2

°

40

40

 Front axle brake disks

Number

Designation

Model 900

Model 906

BA42.10-N-1001-11A

Brake disk bolt

Nm

18

18

Repair materials

Number

Designation

Order number

BR00.45-Z-1001-06A

Long-life grease

A 000 989 63 51 11

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01