Remove/install rear axle brake disk

AR42.10-D-0240TS

Remove/install rear axle brake disk

06.03.2020

Model

907, 910

Modification notes

07.06.2019

Work procedure revised

The whole document

Shown on model 910

1

Brake disk

2

Locking bolt

3

Brake caliper

Shown on model 907 with rear axle 741.422

1

Brake disk

4

Wheel flange

5

Caliper support

6

Screw

 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

 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

 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.Model 907
Model 910

AS00.00-Z-0017-01A

Topical note

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

AH00.00-P-0020-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-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

Topical note

Notes on evaluating brake disks

AH42.10-N-9406-07B



Remove

1

Remove brakepads on rear axle.

AR42.10-D-1710TS

2

Detach brake caliper (3).

AR42.10-D-0080TS

 Do not detach brake hose. Remove brake caliper (3) and tie up.

3

Remove brake caliper support (5).

AR42.10-D-0221TS

4

Increase clearance of brake shoes.

Model 907, 910
except code B25 (Electric parking brake)

 Model 907 except code IT5 (5.0 tons), model 910
To do so, release adjustment wheel of brake adjuster through the bore for wheel bolt.

 Model 907 with code IT5 (5.0 tons)
To do so, release the brake adjuster adjustment screw.

If the parking brake is not released,



Release parking brake.

5.1

Remove safety screw (2) of brake disk (1).

Model 907 with rear axle 741.421/423
Model 910

 To do so, position two wheel bolts and counterhold brake disk (1) with a suitable tool. Then unscrew wheel bolts.

5.2

Remove wheel flange (4).

Model 907 with rear axle 741.422/453/454/455/456, 748

 To do so, remove the bolts (6).

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

6

Remove brake disk (1).



Check

7

Check brake disk (1) for damage and wear.



Assess condition of brake disks

AP42.10-D-4256TS

 Clean contact surfaces of brake disk (1).

Assembly cleaner

*BR00.45-Z-1028-04A

If brake disk (1) is damaged or worn,



replace brake disks (1) and brakepads of the rear axle.

8

Check brakepads for damage and wear.



Assess condition of brake linings

AP42.10-D-4252TS

If the brakepads are reused,



clean contact surfaces on carrier plates of brakepads.

Assembly cleaner

*BR00.45-Z-1028-04A

If a brakepad is damaged or worn,



replace all service brake brakepads on rear axle.

 Dispose of brakepads as special waste. The local authorities can provide information regarding whether disposal is also permitted as industrial waste similar to domestic waste.

If the brakepads are replaced,



also replace all anti-rattle springs.

9

Check anti-rattle springs for damage and wear.

If the anti-rattle springs are reused,



clean anti-rattle springs.

Assembly cleaner

*BR00.45-Z-1028-04A

If the anti-rattle springs are damaged or worn,



replace all anti-rattle springs on respective brake caliper support.

10

Check parking brake for damage and wear.

Model 907, 910
except code B25 (Electric parking brake)

Minimum dimension for brake shoes incl. carrier plate

*BE42.20-N-1001-01TS

If the component parts of the parking brake are damaged or worn,



replace affected components.

 Replace brake shoes of parking brake on both sides of vehicle.

11

Push back existing brake pistons and check for ease of movement.

Model 907, 910
except code B25 (Electric parking brake)

 Resetting device

*000589524300

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



extract brake fluid.

 Commercially available devices/tools
Extraction bellows

If a brake piston is sluggish,



replace brake caliper (3).

Remove/install rear-axle brake caliper

AR42.10-D-0080TS

12

Check brake caliper (3) for damage and leakage.

If the brake caliper (3) is damaged or leaking or a boot of a brake piston is damaged,



replace brake caliper (3).

Remove/install rear-axle brake caliper

AR42.10-D-0080TS

13

Check component parts of brake caliper guide for damage and wear.

If corresponding findings are present,



replace affected components.

Remove/install rear axle brake caliper guide

AR42.10-D-0402TS



Install

14

Lightly grease centering of brake disk (1) at wheel hub.

Long-life grease

*BR00.45-Z-1001-06A

15

Mount brake disk (1).

16.1

Screw in safety screw (2) of brake disk (1).

Model 907 with rear axle 741.421/423
Model 910

 To do so, position two wheel bolts and counterhold brake disk (1) with a suitable tool. Then unscrew wheel bolts.

 Bolt, brake disk to rear axle shaft/wheel hub

*BA42.10-N-1001-13TS

16.2

Install wheel flange (4).

Model 907 with rear axle 741.422/453/454/455/456, 748

 Clean contact surfaces of wheel flange (4).

 Position suitable tool between the two wheel studs for counterholding.
Replace screw/bolts (6).

 Collar bolt, wheel flange ring with brake disk to wheel hub

*BA42.10-N-1002-13TS

17

Adjust basic clearance of parking brake.

Model 907, 910
except code B25 (Electric parking brake)

Model 907 except code IT5 (5.0 tons), model 910

AR42.20-D-0540-02TS

Model 907 with code IT5 (5.0 tons)

AR42.20-D-0540-02TSB

 Model 907
except code B25 (Electric parking brake)
except code IT5 (5.0 tonner)
Model 910
except code B25 (Electric parking brake)Brake adjuster adjustment screw

*BA42.20-N-1003-01TS

 Model 907
with code IT5 (5.0 tonner)
except code B25 (Electric parking brake)Friction value of brake adjuster adjustment screw

*BA42.20-N-1004-01TS

18

Install brake caliper support (5).

AR42.10-D-0221TS

19

Install brake caliper (3).

AR42.10-D-0080TS

20

Install brakepads.

AR42.10-D-1710TS



Check

21

Check fill level in brake fluid reservoir.



Brake system - inspect fluid level

AP42.10-D-4210TS

If the fill level is incorrect,



correct fill level.



Brake fluids (DOT 4 plus)

BB00.40-P-0331-00A

 Commercially available devices/tools
Extraction bellows

22

Perform brake test.



Brake test

AP42.00-D-4290TS

Check values for parking brake

Number

Designation

Model 907, 910
except code B25 (Electric parking brake)

BE42.20-N-1001-01TS

Minimum dimension for brake shoes incl. carrier plate

mm

4,5

 Rear axle brake disks

Number

Designation

Model 907, 910

BA42.10-N-1001-13TS

Bolt, brake disk to rear axle shaft/wheel hub

M8

Nm

18

 Rear axle brake disks

Number

Designation

Model 907, 910

BA42.10-N-1002-13TS

Collar bolt, wheel flange ring with brake disk to wheel hub

M14x1.5

Stage 1

Nm

80

Stage 2

°

40

 Parking brake

Number

Designation

Model 907 except code IT5 (5.0 tons), model 910

BA42.20-N-1003-01TS

Brake adjuster adjustment screw

Nm

-

 Parking brake

Number

Designation

Model 907
with code IT5 (5.0 tonner)
except code B25 (Electric parking brake)

BA42.20-N-1004-01TS

Friction value of brake adjuster adjustment screw

Nm

 5

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