Removing, checking and installing rear axle brake pads

AR42.10-D-1700H

Removing, checking and installing rear axle brake pads

05.06.2014

MODEL

900

MODEL

906

Model 900.63, 906.11/13/21/23/61/63/71/73, shown on model 906.633 with rear axle 741.412

1

Screw

2

Brake caliper

3

Anti-rattle spring

4

Feeler gauge

X88/15

Right rear brake pad contact sensor electrical connection

X88/16

Left rear brake pad contact sensor electrical connection

Model 900.65, 906.15/25/65, shown on model 906.655 with rear axle 741.414

1

Screw

3

Anti-rattle spring

X88/15

Right rear brake pad contact sensor electrical connection

2

Brake caliper

4

Feeler gauge

X88/16

Left rear brake pad contact sensor electrical connection

 Danger !

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer.

AS00.00-Z-0010-01A

 Danger !

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



Brake fluid notes

AH42.50-P-0001-01A



Notes on repairs to brake system

AH42.00-P-0003-01A



Notes on evaluating brake disks

AH42.10-N-9406-07B

 

Remove/install

1

Unscrew lid of brake fluid reservoir

2

Remove rear wheels

Remove/install wheels

AR40.10-D-1100H

3

Disconnect left rear brake pad contact sensor electrical connection (X88/16) or right rear brake pad contact sensor electrical connection (X88/15)


Use straight or angled needle nose pliers.
Otherwise, damage may occur.

4.1

Remove lower bolt (1) on brake caliper (2)

MODEL 900.63, 906.11/13/21/23/61/63/71/73

 Installation: To avoid any noise, the truncation on the bolt head of the screw/bolt (1) must have a gap of approx. 0.5 mm to the contact surface on the brake caliper. To ensure that this is so, when tightening, a feeler gauge (4) 1.0 mm is to be placed between the contact surface on the brake caliper and the truncation on the bolt head.

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

*BA42.10-N-1002-12A

4.2

Undo bolt (1) on top of the brake caliper (2)

MODEL 900.65, 906.15/25/65

 Installation: To avoid any noise, the truncation on the bolt head of the screw/bolt (1) must have a gap of approx. 0.5 mm to the contact surface on the brake caliper. To ensure that this is so, when tightening, a feeler gauge (4) 1.0 mm is to be placed between the contact surface on the brake caliper and the truncation on the bolt head.

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

*BA42.10-N-1002-12A

5

Remove brake linings

 MODEL 900.63, 906.11/13/21/23/61/63/71/73
To do so fold brake caliper (2) upwards.

 MODEL 900.65, 906.15/25/65
To do so, fold the brake caliper (2) downward.

 Remove any dirt or adhesive residue from the lining contact surfaces in the brake caliper body.
Dispose of brake pads as special waste. The local authorities can provide information regarding whether disposal is also permitted as industrial waste similar to domestic waste.

 Installation: Brake linings without adhesive foil: Assembly position of brake caliper on piston side (inside)
Brake linings with adhesive foil: Assembly position of brake caliper on body side (outside). Remove backing and insert brake lining into lining guide.
Always replace brake pad contact sensor.

 MODEL 900.63, 906.11/13/21/23/61/63/71/73
Installation: Install brake pad contact sensor on outer brake pad.

 MODEL 900.65, 906.15/25/65
Installation: Install brake pad contact sensor on inner brake pad.

 Installation: Install brake pad contact sensor on inner brake pad.
When brake caliper is closed again, press body-side lining against brake caliper body in order to fix it in position.

6

Clean brake parts and check for wear and damage

Inspect condition of brake system

AR42.10-D-1600-11A

 Check anti-rattle springs (3) and replace if damaged or plastically deformed.

MODEL 900
MODEL 906

*BE42.10-N-1001-10A

MODEL 900.63
MODEL 900.65
MODEL 906.11/13/21/23/61/63/71/73
MODEL 906.15/25/65

*BE42.10-N-1001-09B

 Caliper gauge

*140589001900

 Brake caliper brush

*000589266800

7

Push back brake piston

Push back piston

AR42.10-D-1600-09A

 If the brake fluid level in the brake fluid reservoir is too high, extract some brake fluid.

 Resetting device

*000589524300

8

Install in the reverse order

9

Build up brake pressure by fully depressing brake pedal several times

10

Check fluid level in brake fluid reservoir, rectify if necessary



Hydraulic brake system - check fluid level, correct if necessary

AP42.50-D-4210H

11

Check brake system for leaks

Check brake system for leaks

AR42.10-S-0100-01S

Test values for rear brake disks

Number

Designation

MODEL 900.63

MODEL 900.65

BE42.10-N-1001-09B

Brake disk thickness

New

mm

16

28

Wear limit

mm

14

25

Max. lateral runout

mm

0,03

0,03

Max. axial runout

mm

0,05

0,05

Repair limit dimension

mm

–

–

Test values for rear brake disks

Number

Designation

MODEL 906.11/13/21/23/61/63/71/73

MODEL 906.15/25/65

BE42.10-N-1001-09B

Brake disk thickness

New

mm

16

28

Wear limit

mm

14

25

Max. lateral runout

mm

0,03

0,03

Max. axial runout

mm

0,05

0,05

Repair limit dimension

mm

–

–

Test and adjustment values for service brake

Number

Designation

MODEL 900

MODEL 906

BE42.10-N-1001-10A

Brake lining wear limit

mm

3

3

 Rear axle brake caliper

Number

Designation

MODEL 900

MODEL 906

BA42.10-N-1002-12A

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

M8

Nm

–

–

M81

Nm

32

32

M10 10.9

Nm

–

–

M101.25

Nm

65

65