Remove/install brake disc - AR42.10-P-0220I

MODEL 215, 220 

Fig 1: Identifying Brake Disc And Bolt

MODIFICATION NOTES

17.12.02	Notes on safety for brake fluid, included for the first time		AS42.50-Z-0001-01A
17.12.02	Check version of pedal assembly, added	Step 10.1	BT42.20-P-0510-01A

	Remove/install
	Risk of injury  to skin and eyes caused by handling hot or glowing objects.	Wear safety gloves, protective clothing and safety glasses, if necessary.	AS00.00-Z-0002-01A
	Notes on repairs to brake system		AH42.00-P-0003-01A
1	Remove wheels
	Remove/install wheels, rotate if necessary		AP40.10-P-4050Z
2	Release parking brake	When removing the brake disks (61) on the rear axle
	Checking
3	Check brake lining thickness and brake disks (61)	Only replace brake pads and brake disks (61) in complete sets if necessary.
	Inspect condition of brake disks		AP42.10-P-4258I
	Check brake lining thickness	If the brake pads have worn down to beyond the wear limit, the bar between the sealing groove and dust cap may be damaged; therefore: ↓	AP42.10-P-4253A
		Check brake system for leaks with pressure tester.	AR42.10-P-0015I
	Clean
4	If necessary, clean the perforation in the brake disks (61)		AR42.10-P-2260-01I
5	Remove brake disk	Do not detach brake hose, instead attach brake caliper to vehicle so that it is free of tension. Do not kink or tension brake hose, as otherwise it will be damaged.
		Remove/install front axle brake caliper.	AR42.10-P-0070I
		Remove/install rear axle brake caliper.	AR42.10-P-0080I
6.1	Preloading automatic cable slack adjuster	When removing the brake disks (61) on the rear axle
		Model 215 except 215.379, Model 220 except 220.179	AR42.20-P-0520-01A
6.2	Release cable slack adjuster	When removing the brake disks (61) on the rear axle
		Model 215.379, model 220.179	AR42.20-P-0520-03IM
			*BA42.20-P-1005-01A
			*129589116300
7	Unscrew locking bolt (64) and remove brake disk (61)	When removing brake disk (61) on rear axle: If parking brake drums are run in, turn back the adjusting mechanism of the parking brake beforehand. Otherwise the brake shoes will be damaged: See Adjust parking brake:
		Model 215 except 215.379, Model 220 except 220.179	AR42.20-P-0540I
		Model 215.379, Model 220.179	AR42.20-P-0540IM
		Installation:  Replace securing bolt (64)
			*BA42.10-P-1001-06A
			*BA42.10-P-1002-06A
	Clean
8	Clean contact surfaces and seat of brake disk (61) if necessary
9	Lightly grease seat of brake disk (61)	Long-life grease	*BR00.45-Z-1001-06A
	Checking
10	Check condition of brake shoes of parking brake	After removing rear axle brake disk (61), if necessary: ↓ Replace parking brake shoes:
		Model 215 except 215.379, Model 220 except 220.179	AR42.20-P-0530I
		Model 215.379, Model 220.179	AR42.20-P-0530IM
11	Install in the reverse order
	Checking
12	Check version of pedal assembly	After installing brake disk (61) on the rear axle
	Parking brake pedal assembly modified		BT42.20-P-0510-01A
13	Adjust parking brake	After installing brake disks (61) on rear axle
		Model 215 except 215.379, Model 220 except 220.179	AR42.20-P-0540I
		Model 215.379, Model 220.179	AR42.20-P-0540IM
14	Release automatic slack adjuster	After installing brake disks (61) on rear axle
		Model 215 except 215.379, Model 220 except 220.179	AR42.20-P-0520-02A

BRAKE DISCS, BRAKE COVER PLATE

Number	Designation		Model 215.373/ 374/375/ 376/378/ 379	Model 220.02/06/07/0 8/12/16/17/18/87
BA42.10-P-1001-06A	Locking bolt of rear axle brake disk	Nm	10	10
BA42.10-P-1002-06A	Locking bolt of front axle brake disk	Nm	10	10

PARKING BRAKE

Number	Designation		Model 215	Model 220
BA42.20-P-1005-01A	Bolt, brake cable at cable slack adjuster	Nm	12	12

Fig 2: Identifying Snap-Release Tool (129 589 11 63 00)

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1001-06A	Long-life grease	A 000 989 63 51