Remove/install pedal assembly

AR29.10-P-0300SN

Remove/install pedal assembly

27.10.10



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



Notes on repairs to brake system

AH42.00-P-0003-01A



Brake fluid notes

AH42.50-P-0001-01A

1

Unscrew bolt (1) and remove pedal head (2)

On left-hand drive vehicles

 Installation: The catch on the brake lever must match the hole on the pedal head (2).



*BA29.10-P-1002-02C

2.1

Remove bellows at brake pedal

On left-hand drive vehicles

AR29.10-P-0340SM

2.2

Remove brake pedal together with the boot

On right-hand steering vehicles

AR29.10-P-0340SN

3

Remove brake pedal module cover

AR29.10-P-0330SM

4

Remove bolts (3) and remove diagonal strut (4)

On model 450.4



*BA61.25-P-1001-01B

5

Unscrew bolts (5) and remove diagonal strut (6) together with the spacer

On model 450.4



*BA61.25-P-1001-01B

6

Unlock and detach plug on stop lamp switch (S9/1)

 Installation: Install and adjust brake light switch (S9/1), see:

Remove/install mechanical stop lamp switch (S9/1)

AR42.10-P-0040MCC

7

Carefully press out low-pressure hoses (9) on master brake cylinder (10)

 Collect brake fluid which runs out in a suitable container.

 Installation: Check seals of low-pressure hoses (9) on master brake cylinder (10) for damage and replace if necessary.

 Pliers

*450589153700



Checking

8

Check screw connections of brake lines (14, 15) with the master brake cylinder (10) for color codings

 Installation: Mark brake lines (14, 15) correspondingly.

AR42.10-P-0013-05SM

"Yellow" locking paint

*BR00.45-Z-1027-07A

"Red" safety paint

*BR00.45-Z-1028-07A

9

Unfasten bolted connections of brake lines (14, 15) with the brake hose (10) and separate

 It is essential to pay attention to cleanliness, clean the area around the assembly area thoroughly if necessary. Only clean the screw connections of the brake lines (14, 15) with compressed air which is absolutely fee from oil or spirit, otherwise insufficient braking effect is to be expected if the brake system is contaminated.

 Installation: Do not damage the threads when positioning the threaded connections as the resulting chippings could cause the entire operating system to fail.

 Collect brake fluid in a suitable container. Seal connections using suitable plugs.



*BA42.10-P-1005-04E

 Box wrench bit

*450589099904

10

Replace brake line (14, 15)

Only if a brake line (14, 15) with red marking has been loosened.

Model 450.3/4 as of 3.1.03 up to 31.12.04

AR42.10-P-0017SN

Model 450.3/4 as of 1.1.05

AR42.10-P-0017SO

11

Remove cable ties (16)

 Installation: Replace cable tie (16).

12

Pull electrical line (7) of the stop lamp switch (S9/1) with the rubber grommet out of the housing (8)

13

Disconnect vacuum line (17) from brake booster (18)

14

Unscrew bolts (19) of pedal assembly (20) from body and take off pedal assembly (20)



*BA29.10-P-1001-02C

15

Install in the reverse order

16

Bleed brake system

AR42.10-P-0010SM

17

Connect STAR DIAGNOSIS and delete fault memory

AD00.00-P-2000-04SM

18

Perform swap check and check the signal from the stop lamp switch (S9/1)

19

Close Star Diagnosis

AD00.00-P-2000-04SM

Number

Designation

Model
450.3/4
Left-hand drive vehicle

Model
450.3/4
Right-hand drive vehicle

BA29.10-P-1001-02C

Bolt, brake pedal module to body

Nm

20

20

BA29.10-P-1002-02C

Bolt, brake pedal head

Nm

9

20

Number

Designation

Model 450.3/4

BA42.10-P-1005-04E

Brake pipe to master brake cylinder

Nm

14

Number

Designation

Model 450.4

BA61.25-P-1001-01B

Bolt, cross strut to substructure

Nm

70

Number

Designation

Order number

BR00.45-Z-1027-07A

"Yellow" locking paint

Lackfabrik Bäder GmbH & Co. KG
Dieselstrasse 34
73734 Esslingen
Germany
Tel. +49 711 381607
Fax +49 711 383092

BR00.45-Z-1028-07A

"Red" safety paint

Lackfabrik Bäder GmbH & Co. KG
Dieselstrasse 34
73734 Esslingen
Germany
Tel. +49 711 381607
Fax +49 711 383092