Modification notes |
29.03.2017 | Überwurfschraube Bremsleitung an Hauptbremszylinder | BA42.10-P-1003-04L | |
29.03.2017 | Überwurfschraube Bremsleitung an Hydraulikeinheit | BA42.10-P-1004-04L | |
06.04.2017 | Retaining screw, brake line to master brake cylinder | BA42.10-P-1003-04L | |
06.04.2017 | Retaining screw, brake line to hydraulic unit | BA42.10-P-1004-04L | |
05.12.2018 | "Partial replacement of brake lines", newly defined. | Operation steps 4, 7 | |
05.12.2018 | "Wax all connections of brake lines", added. | Operation step 14 | |
02.05.2019 | "Determine diameter of brake line", added. | Step 9 | |
02.05.2019 | "Preparatory work for making flange", changed. | Operation step 10 | AR42.10-P-0027-01D |
Shown on brake line (2) with line diameter of 4.75 mm (d) |
1 | Retaining screw |
2 | Brake line |
a | F-flange 115° |
d | Line diameter 4.75 mm |
d2 | Flange diameter 7.1 0.18 mm |
X | Flange height 2.3 0.3 mm |
P42.10-2899-03
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. | |
Topical note | Notes on handling, transport and storage of composite brake disks | ||
Topical note | Notes on handling, transport and storage of ceramic brake disks | ||
Topical note | Brake fluid notes | ||
Topical note | Notes on repairs to brake system | ||
Notes on safety-relevant components | |||
| Remove | ||
1 | Raise vehicle. | ||
2 | Expose installation space of the corresponding brake line (2). | ||
3 | Clean respective brake line connections. | | |
Only use clean, lint free rags and cleaner free of mineral oil. | |||
Assembly cleaner | |||
4 | Remove respective brake line (2) or section of brake line (2). | Always completely replace brake lines (2) with a line diameter of 5.25 mm from master brake cylinder to hydraulic unit and brake lines (2) with flexible section. | |
A partial replacement is only permissible for brake lines (2) with a line diameter of 4.75 mm (d) or 4.95 mm (wheel line). | |||
5 | Seal respective connection fittings and brake lines (2) with suitable stop plugs. | Record plug | |
Prepare brake line (2) | |||
6 | Match length of new brake line (2) to old brake line (2) with the pipe cutter. | Flaring tool | |
7 | Separate new brake line (2) into sections using pipe cutter. | If required for installation. Not for brake lines (2) with a line diameter of 5.25 mm. | |
Two connecting points per new brake line (2) are permitted. | |||
The connecting point must be in perfect condition and it must not be soiled. | |||
Flaring tool | |||
8 | Slide retaining screws (1) onto brake line (2). | Use specified line connectors only. | |
9 | Determine diameter of new brake line (2). | Depending on the coating, brake lines (2) with a line diameter of 4.75 mm (d), a line diameter 4.95 mm or a line diameter 5.25 mm are used. | |
10 | Make flange on brake line (2). | ||
Brake lines (2) with a line diameter of 4.75 mm (d) are flanged without peeling and making first-stage flange. | |||
Make F-flange 115° (a) in accordance with DIN 74234. | |||
Screw, clamping plate to flanging tool kit | |||
Stamp holder in flanging tool kit (post-flanging) | |||
Stamp holder in flanging tool kit (pre-flanging) | |||
ATE brake cylinder paste, article no.: 03.99020501.2 | |||
Flaring tool | |||
11 | Adapt new brake line (2) with a bending tool so that it follows the routing path of the old brake line (2). | The bending radius must not be less than 13 mm. | |
Flaring tool | |||
| Install | ||
12 | Install new brake line (2). | ||
Note on calculation of tightening torque when using insertion or socket tools with various effective lengths | |||
When routing the brake line (2) make sure there is sufficient distance to other components. There must be no stress, kinking and line narrowing. | |||
Use specified line connectors only. | |||
Model 221 (except 221.074/077/174/177/179)Union nut, brake line to T-piece | |||
Model 213, 238, 257, 290, 293Retaining screw, brake line to threaded socket | |||
Model 213, 238, 257, 290, 293Retaining screw, brake line to hydraulic unit | |||
Model 213, 238, 257, 290, 293Retaining screw, brake line to master brake cylinder | |||
Model 166, 167, 292Brake pipe to master brake cylinder | |||
Model 216, 221Union nut, brake line to brake caliper | |||
Model 216, 221Union nut, brake line to hydraulic unit | |||
Model 216, 221Union nut, brake line to master brake cylinder | |||
Model 205, 253Retaining screw, brake line to threaded socket | |||
Model 205, 253Retaining screw, brake line to hydraulic unit | |||
Model 205, 253Retaining screw, brake line to master brake cylinder | |||
Model 217, 222Retaining screw, brake line to brake line (connecting point) | |||
Model 217, 222Retaining screw, brake line to threaded socket | |||
Model 217, 222Retaining screw, brake line to hydraulic unit | |||
Model 217, 222Retaining screw, brake line to master brake cylinder | |||
Model 117, 156, 172, 176, 204, 207, 212, 218, 231, 242, 246Retaining screw, brake line to threaded socket | |||
Model 117, 156, 172, 176, 204, 207, 212, 218, 231, 242, 246Retaining screw, brake line to hydraulic unit | |||
Model 117, 156, 172, 176, 204, 207, 212, 218, 231, 242, 246Retaining screw, brake line to master brake cylinder | |||
Model 118, 177, 247Retaining screw, brake line to threaded socket | |||
Model 118, 177, 247Retaining screw, brake line to master brake cylinder | |||
Model 118, 177, 247Retaining screw, brake line to hydraulic unit | |||
Model 251Brake pipe to master brake cylinder | |||
Model 251Brake line to floating brake caliper | |||
Model 251Brake line to brake hose | |||
Model 213, 238, 257, 290, 293Retaining screw, brake line to brake hose | |||
Model 118, 177, 247Retaining screw, brake line to brake hose | |||
Model 217, 222Retaining screw, brake line to brake hose | |||
Model 205, 253Retaining screw, brake line to brake hose | |||
Model 117, 156, 172, 176, 204, 207, 212, 218, 231, 242, 246Retaining screw, brake line to brake hose | |||
Model 216, 221Retaining screw, brake line to brake hose | |||
Model 166, 167, 292Brake line to brake hose | |||
Adapter coupling | |||
Torque tool set | |||
13 | Check surface of new brake line (2) for damage as a result of scratches and paint damage. | In the event of a problem, | |
| |||
repair the paint damage. | |||
Zinc dust paint spray can | |||
14 | Wax all connections of brake lines (2). | Use commercially available wax. | |
15 | Bleed brake system. |
| |
Model 213, 238 | |||
Model 257, 290 | |||
Model 118, 177, 247 | |||
Model 205, 253, 293 | |||
Model 217, 222 | |||
Model 231 | |||
Model 166, 172, 204, 292 | |||
Model 207, 212, 218 | |||
Model 117, 156, 176, 242, 246 | |||
Model 251 | |||
Model 216, 221 | |||
16 | Perform brake test on test stand. | ||
|
001 589 00 16 00
Adapter coupling
000 589 20 99 00
Flaring tool
003 589 05 09 00
Torque tool set
129 589 00 91 00
Record plug
Repair materials |
Number | Designation | Order number |
BR00.45-Z-1028-04A | Assembly cleaner | Adolf Würth GmbH & Co. KG |
BR00.45-Z-1055-07A | Zinc dust paint spray can | A 000 986 82 42 09 |
BR00.45-Z-1078-06A | ATE brake cylinder paste, article no.: 03.99020501.2 | ATE, a brand of the Continental Corporation |
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