Remove/install front axle brake caliper

AR42.10-G-0070BB

Remove/install front axle brake caliper

04.02.2020

Model

405.102/103/122/123/200/201/220/221

Model

405.105/110/125/202/222 ## up to 260530

Model

437.43# ## up to 262508 with front axle 737.222

Model

437.437 with front axle 737.223

Model

437.46 with front axle 737.224

1

Brake line

2

Brake caliper

3

Bolts

4

Diaphragm brake cylinder

5

Fastening bracket

6

Brake lever

 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

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

 

Remove/install

1

Remove front wheel.

AR40.10-G-1100F

2

Remove protective shield on inside of brake caliper (2).

Only on model 437 with front axle 737.222/223/224 with code A23 (Protective shield for brake calipers (for LSB)) or only on model 437.437 with front axle 737.223 with code UA28 (Hub reduction gear encapsulation, for extreme sludge service)

Model 437.437 with front axle 737.223
with code UA28 (Hub reduction gear encapsulation, for extreme muddy conditions)
except code R99 (Drop center rims DW 15Lx24 ET 135)

AR42.10-G-0840UC

Model 437.437 with front axle 737.223
with code R99 (Drop center rims DW 15Lx24 ET 135)
with code UA28 (Hub reduction gear encapsulation, for extreme muddy conditions)

AR42.10-G-0840UH

 Model 437 with front axle 737.222/223/224 with code A23 (Protective shield for brake calipers (for LSB))
There are no reference documents for these models.

 Only on model 437 with code A23 (Protective shield for brake calipers (for LSB))Screw, shield plate to hub reduction gear

*BA42.10-N-1005-06A

3

Remove brake pads.

AR42.10-G-1610BB

4

Remove brake line (1) from diaphragm brake cylinder (4).

5

Remove holder of electric line for brake pad wear sensor.

 Depending on the model and version involved, the brake pad wear sensor is only installed on the left-hand side of the vehicle.

6

Remove screw/bolts (3).

 Installation: Replace bolts (3).
Apply coating of Loctite Anti-Seize to thread of screws (3).

 Bolt, brake caliper to hub reduction gear housing

*BA42.10-N-1001-10F

Loctite anti-seize

*BR00.45-Z-1048-06A

7

Remove brake caliper (2).

8

Remove diaphragm brake cylinder (4), mounting support (5) and brake lever (6) from brake caliper (2).

If the brake caliper (2) is replaced or repaired.

Model 405, 437

AR42.10-G-0670BB



Clean

9

Clean threaded holes for screws (3) in brake caliper (2).

Loctite 7063 (400 ml) cleaning spray

*BR00.45-Z-1046-04A

10

Clean contact surfaces between brake caliper (2) and hub reduction gear housing.

11

Install in the reverse order.



Check

12

Check brake system for leak tightness and proper operation.

 Front axle brake caliper

Number

Designation

Model 405.102/122/200/210/220/230

Model 405.103/123/201/221

BA42.10-N-1001-10F

Bolt, brake caliper to hub reduction gear housing

Nm

340

340

 Front axle brake caliper

Number

Designation

Model 405.105/110/125/202/222 ## up to 260530

Model 437.43# ## up to 262508 with front axle 737.222

BA42.10-N-1001-10F

Bolt, brake caliper to hub reduction gear housing

Nm

340

340

 Front axle brake caliper

Number

Designation

Model 437.437 with front axle 737.223

Model 437.46 with front axle 737.224

BA42.10-N-1001-10F

Bolt, brake caliper to hub reduction gear housing

Nm

340

340

 Brake system encapsulation

Number

Designation

Model 437.4 with code A23

BA42.10-N-1005-06A

Screw, shield plate to hub reduction gear

M6

Nm

7,5

M10

Nm

51

Repair materials

Number

Designation

Order number

BR00.45-Z-1046-04A

Loctite 7063 (400 ml) cleaning spray

A 001 986 71 71 09

BR00.45-Z-1048-06A

Loctite anti-seize

A 002 989 56 51 09