Remove/install rear-axle brake caliper

AR42.10-D-0080FD

Remove/install rear-axle brake caliper

10.05.2017

Model

909.63

Shown on left side of vehicle

1

Screw

2

Brakepad wear sensor electrical line

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 wheel and tire assembly from rear axle

AR40.10-D-1100F

2

Disconnect brakepad wear sensor (6) from brakepad wear sensor electrical line (2)

3

Unscrew screw (1) and place brakepad wear sensor electrical line (2) to one side

 Installation: Replace screw (1).

 Bolt, wear indicator to brake caliper

*BA42.10-N-1004-12A

4

Remove retaining spring (8)

5

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

6

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

 To remove the brake caliper (5), it may be necessary to push back the piston of the brake caliper (5) slightly.

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

*BA42.10-N-1002-12A

 Resetting device

*000589524300

7

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

 Installation:
Do not install the brake hose (3) twisted and make sure that it is routed so that it cannot chafe.
Otherwise the brake hoses will be damaged and the brake system will fail.

 Installation: Check brake hose (3) for cracks and chafe marks, and 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 disk

Brake disk thickness

*BE42.10-N-1001-09B

If there is damage or if the wear limit is undershot



Replace brake disk.

AR42.10-D-0240FC

10

Check brake pads

Brake lining wear limit

*BE42.10-N-1001-10A

If there is damage or if the wear limit is undershot



Replace brake linings.

AR42.10-D-1700FD

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 rear axle brake disks

Number

Designation

Model 909.63

BE42.10-N-1001-09B

Brake disk thickness

New

mm

16

Wear limit

mm

14

Max. lateral runout

mm

0,1

Max. axial runout

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

 Rear axle brake caliper

Number

Designation

Model 909.63

BA42.10-N-1002-12A

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

M8

Nm

25

M81

Nm

-

M10 10.9

Nm

30

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 909.63

BA42.10-N-1004-12A

Bolt, wear indicator to brake caliper

M6

Nm

10