Remove/install front axle brake caliper

AR42.10-D-0070FA

Remove/install front axle brake caliper

28.03.2018

Model

909.63

Shown on left

1

Screw

2

Electrical cable for wear indicator

3

Brake hose

4

Guide pin

5

Brake caliper

6

Brake wear sensor

7

Dust caps

8

Retaining spring

 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

 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

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Topical note

Notes on evaluating brake disks

AH42.10-N-9406-07B

Topical note

Brake fluid notes

AH42.50-P-0001-01A

Topical note

Notes on repairs to brake system

AH42.00-P-0003-01A

Note on calculation of tightening torque when using insertion or socket tools with various effective lengths

AH00.00-P-0015-01CW

 

Remove/install

1

Remove corresponding complete wheel

AR40.10-D-1100F

2

Disconnect brakepad wear sensor (6) from electric line of wear indicator (2)

3

Remove screw/bolt (1) and place wear indicator electric line (2) to one side

 Installation: Replace screw/bolt (1).

 Bolt, wear indicator to brake caliper

*BA42.10-N-1003-10A

4

Remove retaining spring (8)

5

Remove dust caps (7) of guide pins (4)

6

Remove guide pins (4) and remove brake caliper (5)

 When removing the brake caliper (5), gently press back the piston of the brake caliper (5) if necessary.

 Bolt, top section of brake caliper to brake caliper support

*BA42.10-N-1005-10A

 Resetting device

*000589524300

7

Remove brake hose (3) from brake line and close off openings using suitable stop plugs

 Installation:
Do not install the brake hose (3) twisted and make sure that it can move freely.
Otherwise, the brake hose (3) may be damaged and the brake system may fail.

 Installation: Check brake hose (3) for cracks and chafe marks, replace if necessary.

 Threaded connection, brake line to brake hose

*BA42.10-N-1001-04A

 Torque wrench

*001589752100

 Record plug

*129589009100

 Box wrench bit

*000589750300

8

Detach brake hose (3) from brake caliper (5) and seal openings using suitable stop plugs

When replacing the brake caliper (5).

 Threaded connection, brake hose to brake caliper

*BA42.10-N-1004-04A

 Box wrench bit

*000589750300

 Record plug

*129589009100

 Torque wrench

*001589752100

9

Check brake pads

Brake lining wear limit

*BE42.10-N-1001-10A

In case of damage or the wear limit is undershot



Replace brake linings.

AR42.10-D-1600FA

10

Check brake disks

Brake disk

*BE42.10-N-1001-08B

In case of damage or the wear limit is not reached.



Replace brake disk.

AR42.10-D-0230FA

11

Install in the reverse order

12

Bleed brake system

AR42.10-D-0010F

13

Check brake system for leaks

AR42.10-D-0100-01F

14

Check fluid level in the brake fluid reservoir, correct if necessary



AP42.50-D-4210F

Check values for front axle brake disks

Number

Designation

Model 909

BE42.10-N-1001-08B

Brake disk

Thickness when new

mm

22

Wear limit

mm

19

Lateral runout

mm

 0,05

Flatness deviation

mm

 0,02

Repair limit dimension

mm

-

Test and adjustment values for service brake

Number

Designation

Model 909

BE42.10-N-1001-10A

Brake lining wear limit

mm

2

 Brake hoses, brake lines

Number

Designation

Model 909

BA42.10-N-1001-04A

Threaded connection, brake line to brake hose

M101

Nm

14

 Front axle brake caliper

Number

Designation

Model 909

BA42.10-N-1003-10A

Bolt, wear indicator to brake caliper

M6

Nm

10

 Brake hoses, brake lines

Number

Designation

Model 909

BA42.10-N-1004-04A

Threaded connection, brake hose to brake caliper

Nm

24

 Front axle brake caliper

Number

Designation

Model 909

BA42.10-N-1005-10A

Bolt, top section of brake caliper to brake caliper support

M10

Nm

30