Reconditioning brake caliper guide

AR42.10-D-0400HA

Reconditioning brake caliper guide

17.6.11

 

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

Remove wheels

AR40.10-D-1100H

2

Press back brake pads (8) using a suitable tool

 If the brake fluid level in the reservoir is too high, suction off a little brake fluid.

3

Disconnect right front brake pad contact sensor connector (X88/13) or left front brake pad contact sensor connector (X88/14)

 Use straight or angled needle nose pliers.

4

Remove dust caps (1) in top and bottom of brake caliper (3)

 Installation: Replace dust caps (1). Clean dust cap seat and coat with lubricating grease from the repair kit. Pay attention to correct seat of dust caps (1).

Grease

*BR00.45-Z-1092-06A

5

Remove bolts (2)



*BA42.10-N-1004-10H

6

Remove brake caliper (3)

 Tie up brake caliper (3). Ensure that the brake hose is not subjected to tensile loads or angular movement.

7

Remove brake pads (8)

 Installation: When installing the old brake pads (8), install them again where they were removed from.

8

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

 Installation: Replace anti-rattle springs (9). Clean contact surfaces on brake caliper bracket.

9

Clean brake parts and check for wear and damage

AR42.10-D-1600-11A

Brake lining wear limit

*BE42.10-N-1001-10A

Front axle brake disks

*BE42.10-N-1001-08B

 Caliper gauge

*124589051900

 Brake caliper brush

*000589266800

 If the wear limit has been reached, install new brake disks.

See: 

Remove/install brake disks of front axle

AR42.10-D-0230H

10

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

 First press guide pin (5, 6) out of guide in direction of brake disk, then remove boots (7).

 Installation: Clean seat of guide pins (5, 6). Coat guide pins (5, 6), guide bore and boots (7) with lubricating grease from repair kit. First insert boots in the groove of the brake caliper (3), then push guide bolts (5, 6) into the guide from outside to inside towards the brake disk as when dismantling.

Ensure that the boots (7) are correctly located in the groove of the guide pins (5, 6), otherwise the brake caliper (3) will no longer be able to move freely. Wipe off excess lubricating grease.

 Installation: Replace guide pins (5, 6). Install guide pin (5) with rubber ring (4) at the top, install guide pin (6) without rubber ring at the bottom. Allow existing air to escape from the boots (7). To do this, lift the boot (7) at one point slightly out of the groove of the guide pin (5, 6) and press out the air.

Grease

*BR00.45-Z-1092-06A

11

Install in the reverse order

12

Build up brake pressure by fully depressing brake pedal several times

13

Check fluid level in reservoir, correct if necessary

Only when installing new brake linings (8).

AP42.50-D-4210H

14

Check brake system for leaks

AR42.10-S-0100-01S

Number

Designation

Model
900

Model
906

BE42.10-N-1001-08B

Brake disk

Thickness when new

mm

28

28

Wear limit

mm

25

25

Lateral runout

mm

0.03

0.03

Flatness deviation

mm

0.04

0.04

Repair limit dimension

mm

-

-

Number

Designation

Model
900

Model
906

BE42.10-N-1001-10A

Brake lining wear limit

mm

3

3

Number

Designation

Model 900

Model 906

BA42.10-N-1004-10H

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

M8

Nm

34

34

M10/10.9

Nm

-

-

Number

Designation

Order number

BR00.45-Z-1092-06A

Lubricating grease (Brembo brake caliper guide)

A 002 989 51 51