Remove/install front axle brake caliper guide

AR42.10-D-0401TS

Remove/install front axle brake caliper guide

06.03.2020

Model

907, 910

Modification notes

07.06.2019

Work procedure revised

The whole document

Shown on model 907 with code IT5 (5.0 tons), left side of vehicle

1

Dust caps

2

Bolts

3

Brake caliper

4

Guide ring

5

Guide pin

6

Guide pin

7

Bellows

8

Brake linings

9

Anti-rattle 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

Brake fluid notes

AH42.50-P-0001-01A

Topical note

Notes on repairs to brake system

AH42.00-P-0003-01A



Remove

1

Remove brakepads (8).

AR42.10-D-1610TS

2

Remove respective brake caliper (3).

AR42.10-D-0070TS

 Do not detach brake hose.
Dispose of dust caps (1) and bolts (2).

3

Remove anti-rattle springs (9) from brake caliper support.

 Dispose of anti-rattle springs (9).

4

Remove guide pins (5, 6) and boots (7).

 Firstly push guide pins (5, 6) out of guide in direction of brake disk; then remove boots (7).

 Dispose of guide pins (5, 6) and boots (7).



Clean

5

Clean contact surfaces on brake caliper support.

 Brake caliper brush

*000589266800

6

Clean dust cap seat and coat with lubricating grease from repair kit.

7

Clean seats of guide pins (5, 6).

Assembly cleaner

*BR00.45-Z-1028-04A



Check

8

Check brakepads (8) for damage and wear.



Assess condition of brake linings

AP42.10-D-4252TS

If corresponding findings are present,



Replace brakepad (8) on front axle.

9

Check brake disk for damage and wear.



Assess condition of brake disks

AP42.10-D-4256TS

If corresponding findings are present,



replace front axle brake disks.

Remove/install front axle brake disk

AR42.10-D-0230TS

10

Check brake caliper (3) for damage and leakage.

If the brake caliper (3) is damaged or leaking or a boot of a brake piston is damaged,



replace brake caliper (3).

Remove/install front axle brake caliper

AR42.10-D-0070TS



Install

11

Coat new guide pins (5, 6), new boots (7) and guide bores in the brake caliper (3) with lubricating grease from repair kit.

12

Install boots (7) in grooves on brake caliper (3) from brake disk side.


Make sure that the boots (7) are seated correctly in the grooves on the brake caliper (3).
Otherwise, the brake caliper (3) can no longer move freely.

13

Install guide pins (5, 6).


Ensure that the boots (7) are seated correctly in grooves of guide pins (5, 6).
Otherwise, the brake caliper (3) can no longer move freely.

 Install guide pin (5) with guide ring (4) in upper guide bore and guide pin (6) in lower guide bore.

 Push each of the guide pins (5, 6) into each guide bore from outside in direction of brake disk.
Remove excess lubricating grease.

14

Allow existing air to escape from the boots (7).


Make sure that the boots (7) are correctly seated on the brake caliper (3).
Otherwise, malfunction or damage can occur.

 For this, lift respective boot (7) at one point a little out of the groove of the respective guide pin (5, 6) and allow air to escape.

15

Install new anti-rattle springs (9) on brake caliper support.

16

Install brake caliper (3).

AR42.10-D-0070TS

 Use new dust caps (1) and bolts (2).

17

Install brakepads (8).

AR42.10-D-1610TS

If the brakepads (8) are reused,



install brakepads (8) at previous positions.

18

Build up brake pressure by fully depressing brake pedal several times.

19

Check fill level in brake fluid reservoir.

If the brakepads (8) have been replaced.



Brake system - inspect fluid level

AP42.10-D-4210TS

If the fill level is incorrect,



correct fill level.



Brake fluids (DOT 4 plus)

BB00.40-P-0331-00A

 Commercially available devices/tools
Extraction bellows



Check

 Warning

Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.

Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

20

Check brake system for leaks.

AR42.10-D-0100-01TS

21

Perform brake test.



Brake test

AP42.00-D-4290TS

Repair materials

Number

Designation

Order number

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01