Replacing and installing brake pads

AR42.10-P-0170FG

Replacing and installing brake pads

21.4.08

31.3.08

Check brake pads and brake drums as well as appropriate BE, added

Step 12

 

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



Brake fluid notes

AH42.50-P-0001-01A



Notes on repairs to brake system

AH42.00-P-0003-01A

1

Release handbrake lever (2)

2

Lift cover (3) at rear and pull out beverage holder (1)

3

Loosen nut (4) and unhook hand brake cable (6) from the rocker of hand brake lever (5)

4

Remove left or right rear wheel

AR40.10-P-1100FF

5

Counterhold guide pin (9) and unscrew bolts (8) from brake caliper (7)

 Replace bolts (8).



*BA42.10-P-1001-12A

6

Detach brake caliper (7) from brake caliper support (10)

 When the brake caliper (7) is removed, do not depress the brake pedal as otherwise the brake piston (13) will be pressed out of the housing and the brake caliper (7) may be damaged.

 Installation: When inserting the brake caliper (7) ensure that the springs (arrows) of the brake pads (11) are clamped under the brake caliper (7).

7

Remove brake pads (11) with clip (12)

 Installation: Observe correct installation position of clip (12).

8

Push back brake piston (13) of brake caliper (7) using resetting device (14)

 The fluid level in the brake fluid reservoir rises when the brake piston (13) is pushed back. Ensure that the brake fluid reservoir does not overflow. It must be possible to move the brake piston (13) easily.



*454589004300

9

Clean contact surface of brake pads (11) on brake caliper support (10) and on brake caliper (7)

 Installation: Apply a thin coating of brake paste to the contact surfaces on the brake caliper support (10) and on the brake caliper (7).

Brake paste

*BR00.45-Z-1060-06A

10

Pull guide pin (9) out of brake caliper support (10) and check bellows (15) for damage

 Check the ease of movement of the guide pins (9), if the guide pins (9) movement is sluggish, the brake caliper (7) should be replaced otherwise there is the risk of uneven braking effect.

 Installation: Replace damaged bellows (15). Apply a thin coating of brake paste to the guide pins (9) and ensure that the bellows (15) are properly seated.

Brake paste

*BR00.45-Z-1060-06A

11

Check brake caliper (7) for leaks and dust boot (16) on the brake piston (13) for damage

 If the brake caliper (7) is leaky or the dust boot (16) is damaged, the brake caliper (7) should be replaced otherwise there is a risk of uneven braking effect.



Checking

12

Check wear and condition of brake pads (11) and brake disk using vernier caliper; replace if necessary

Brake disk thickness

*BE42.10-P-1001-09F

Brake pad thickness

*BE42.10-P-1001-15F



*450589011900

13

Install in the reverse order

 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 engine, actuate brake pedal several times until the pressure is built up and maintained in the brake system.

AS42.50-Z-0002-01A

14

Operate the brake pedal several times until the brake pads (11) contact the brake disks

 Firm resistance of the brake pedal should be noticeable.

15

Adjust parking brake

AR42.20-P-0540FF

16

Check brake fluid in brake fluid reservoir and correct if necessary.

 Fill up or extract brake fluid to the MAX mark on the brake fluid reservoir in order to guarantee faultless function of the brake system.



General brake fluid

Sheet 330.1

BB00.40-P-0330-01A



Brake fluids (DOT 4 plus)

Sheet 331.0

BB00.40-P-0331-00A

Number

Designation

Model
454.0
with code 30Y

BE42.10-P-1001-09F

Brake disk thickness

New

mm

10

Wear limit

mm

8

Number

Designation

Model
454.0
with code 30Y

BE42.10-P-1001-15F

Brake pad thickness

New (with pad backing plate and shim)

mm

16.4

Wear limit
(with pad backing plate and shim) for maintenance service

mm

7.6

Number

Designation

Model
454.0
with code 30Y

BA42.10-P-1001-12A

Bolt, brake caliper to brake caliper support

Nm

25

Number

Designation

Order number

BR00.45-Z-1060-06A

Brake paste

Q0007414V000000000