Remove/install rear-axle brake caliper

AR42.10-D-0080FC

Remove/install rear-axle brake caliper

10.05.2017

Model

909.64

Model

909.8

Shown on model 909.8 on left side of vehicle

2

Brake linings

4

Brake caliper

5

Screw

6

Brake wear sensor

 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

Notes on repairs to brake system

AH42.00-P-0003-01A

Topical note

Brake fluid notes

AH42.50-P-0001-01A

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 respective wheel and tire assembly from rear axle

AR40.10-D-1100F

2

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

3

Detach brakepad wear display electric line on brake caliper (4)

 Installation: Replace bolt.

 Bolt, wear indicator to brake caliper

*BA42.10-N-1004-12A

4

Remove bolts (5) and remove brake caliper (4)

 Press piston of brake caliper (4) back if necessary.

 Installation: When replacing the brake caliper (4), only install brake calipers (4) from the same manufacturer on the same axle.

 Installation: Replace screw/bolts (5).

 Guide pin/catch bolt, top section of brake caliper to brake caliper support

*BA42.10-N-1002-12A

 Resetting device

*000589524300

5

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

 Installation:
Do not install the brake hose twisted and ensure chafe-free routing.
Otherwise, the brake hose may be damaged and the brake system may fail.

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

 Threaded connection, brake line to brake hose

*BA42.10-N-1001-04A

 Box wrench bit

*000589750300

 Record plug

*129589009100

 Torque wrench

*001589752100

6

Detach brake caliper (4) from brake hose and seal openings using suitable stop plugs

When replacing brake caliper (4).

 Threaded connection, brake hose to brake caliper

*BA42.10-N-1004-04A

 Torque wrench

*001589752100

 Record plug

*129589009100

 Box wrench bit

*000589750300

7

Check brake disk

Brake disk thickness

*BE42.10-N-1001-09B

In case of damage or the wear limit is undershot



Replace brake disk.

AR42.10-D-0240FB

8

Check brakepads (2)

Brake lining wear limit

*BE42.10-N-1001-10A

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



Replace brakepads (2).

AR42.10-D-1700FC

9

Install in the reverse order

10

Bleed brake system

AR42.10-D-0010F

11

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



AP42.50-D-4210F

Check values for rear axle brake disks

Number

Designation

Model 909.64

Model 909.8

BE42.10-N-1001-09B

Brake disk thickness

New

mm

22

22

Wear limit

mm

19

19

Max. lateral runout

mm

0,1

0,1

Max. axial runout

mm

0,02

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

 Rear axle brake caliper

Number

Designation

Model 909.64

Model 909.8

BA42.10-N-1002-12A

Guide pin/catch bolt, top section of brake caliper to brake caliper support

M8

Nm

25

25

M81

Nm

-

-

M10 10.9

Nm

-

-

M101.25

Nm

-

-

 Brake hoses, brake lines

Number

Designation

Model 909

BA42.10-N-1004-04A

Threaded connection, brake hose to brake caliper

Nm

24

 Rear axle brake caliper

Number

Designation

Model 909.64

Model 909.8

BA42.10-N-1004-12A

Bolt, wear indicator to brake caliper

M6

Nm

10

10