Replacing and installing brake pads

AR42.10-P-0170FF

Replacing and installing brake pads

21.4.08

31.3.08

Check brake pads and brake drums as well as appropriate BE, added

Step 9

 

Remove/install

 Danger!

Risk of poisoning caused by swallowing brake fluid. Risk of injury caused by brake fluid coming into contact with skin and eyes.

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



Brake fluid notes

AH42.50-P-0001-01A



Notes on repairs to brake system

AH42.00-P-0003-01A

1

Remove front wheels

AR40.10-P-1100FF

2

Remove bolt (2) from brake caliper (1)

 When loosening the bolt (2) counterhold the guide bolt (3).

 Installation: Install new bolt (2).



*BA42.10-P-1001-10A

3

Fold brake caliper (1) upwards

 Installation: When folding down the brake caliper (1) ensure that the springs (6) of the brake pads (4) are clamped under the brake caliper (1).

4

Take out brake pads (4)

 When the brake pads (4) are removed, do not depress the brake pedal otherwise the brake piston (7) is pushed out of the housing and the brake caliper (1) may be damaged.

 Observe installation position of clamp (8).

5

Press back brake piston using pusher tool (7)

 The fluid level in the brake fluid reservoir rises when the brake piston (7) is pushed back. Ensure that the reservoir does not overflow. It must be possible to move the brake piston (7) easily.



*454589004300

6

Clean contact surface of brake pads (4) on brake caliper support (5) and on brake caliper (1)

 Installation: Apply a thin coating of brake paste to the contact surfaces on the brake caliper support (5), on the brake caliper (1) and on the brake pad (4).

*BR00.45-Z-1060-06A

7

Detach brake caliper (1) inward from brake caliper support (5) and check guide pins (3, 9) and boots (10)

 Damaged bellows (10) should be replaced. Check the ease of movement of the guide bolts (3, 9), if the guide bolts are notchy or sluggish (3, 9) they should be replaced, otherwise the satisfactory function of the brake system is not guaranteed.

 Installation: Apply a thin coating of brake paste to the guide bolt (3, 9) and pay attention to correct seating of the bellows (10).

*BR00.45-Z-1060-06A

8

Check brake caliper (1) for leaks and dust boot on brake piston (7) for damage

 If the brake caliper (1) is leaking or the dust boot on the brake piston (7) is damaged the brake caliper (1) must be replaced. Refer to: 

Remove/install front axle brake caliper

AR42.10-P-0070FF



Checking

9

Check wear and condition of brake pads (4) and brake disk using vernier caliper; replace if necessary

Brake pad thickness

*BE42.10-P-1001-05G

Brake disk thickness

*BE42.10-P-1001-08E



*450589011900

10

Install in the reverse order

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

AS42.50-Z-0002-01A

11

Operate the brake pedal several times until the brake pads (4) contact the brake disks

 Firm resistance must be noticeable.

12

Check brake fluid in the brake fluid
reservoir and correct if necessary

 Fill up or suction off brake fluid to the MAX mark on the brake fluid reservoir in order to guarantee faultless function of the brake system.



General brake fluid

Sheet 330.1

BB00.40-P-0330-01A



Brake fluids (DOT 4 plus)

Sheet 331.0

BB00.40-P-0331-00A

Number

Designation

Model
454.0

BE42.10-P-1001-05G

Brake pad thickness

New (with pad backing plate and shim)

mm

17.3

Wear limit (without pad backing plate) for maintenance service

mm

1.5

Wear limit (with pad backing plate and shim) for maintenance service

mm

7.4

Response of wear indicator (with pad backing plate and shim)

mm

7.4

Number

Designation

Model
454.0

BE42.10-P-1001-08E

Brake disk thickness

New

mm

24

Wear limit

mm

21.5

Number

Designation

Model
454.0

BA42.10-P-1001-10A

Bolt, brake caliper to brake caliper support

Nm

30

Number

Designation

Order number

BR00.45-Z-1060-06A

Brake paste

Q0007414V000000000