Removing/installing brake disk, brake caliper and pads of rear wheel brake - AR42.10-P-0250EW
MODEL 207, 212 (except 212.074/075/076/077/092/274/275/276/277/292)
MODIFICATION NOTES
| 29.11.11 | Long-life grease repair materials replaced by hot-grease paste | Step 21 |
| Remove/install | |||
| 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 | |
| Risk of injury . Skin or eye injuries may result when handling hot or glowing objects. | Wear protective gloves, protective clothing and safety glasses, if necessary. | AS00.00-Z-0002-01A | |
| Notes on repairs to brake system | AH42.00-P-0003-01A | ||
| Brake fluid notes | AH42.50-P-0001-01A | ||
| Notes on self-locking nuts and bolts | AH00.00-N-0001-01A | ||
| Notes on installing brake wear indicator contact sensors | AH42.10-P-0003-01CW | ||
| 1 | Clean area around cap on expansion reservoir for brake fluid | ||
| 2 | Unscrew the cap on the brake fluid expansion reservoir and suction off some brake fluid | ||
| 3 | Remove rear wheels | ||
| MODEL 207 | AP40.10-P-4050CW | ||
| MODEL 212 | AP40.10-P-4050EW | ||
| 4 | Detach spring (1) from brake caliper (2) | ||
| 5 | Detach brake wear sensor (S10/4) from electrical connector (S10/4x1) | ||
| 6 | Pry off and remove protective caps (3) from boots (4) | ||
| 7 | Remove both guide pins (5) | *BA42.10-P-1004-12J | |
| 8 | Remove brake caliper (2) from brake caliper support (8) | Do not tension or kink brake hose (7). To relieve the load on the brake hose (7), fasten the brake caliper (2) to the vehicle free of tension. Otherwise, the brake hose (7) will be damaged. |
|
| 9 | Take out brake pads (6) | ||
| Measure | |||
| 10 | Check brake pads (6) and brake disk (9) for condition and measure wear | ||
| Check brake lining thickness | ENGINE 207, 212 | AP42.10-P-4253A | |
| Inspect condition of brake disks | ENGINE 207, 212 | AP42.10-P-4258EW | |
| 11 | Check brake caliper (2) and dust boot (10) on brake piston for damage | ||
| 12 | Check boots (4) on brake caliper (2) for damage | ||
| 13 | Press back brake piston using pusher tool (01) | ||
| Fig 4 | |||
| Clean | |||
| 14 | Clean contact surfaces of brake pads (6) on brake caliper (2) and brake caliper support (8) using rags | Do not damage the dust boot (10) at the brake piston, do not use any sharp-edged or pointed objects. Otherwise, the brake caliper (2) or brake caliper support (8) will be damaged and have to be replaced. |
|
| Assembly cleaner | *BR00.45-Z-1028-04A | ||
| 15 | Pull brake wear sensor (S10/4) out of pad backing plate of brake pad (6) | ||
| Only carry out steps 16 and 17 when removing/installing the brake caliper (2) | |||
| 16 | Remove bolt (14) and remove electrical connector (S10/4x1) from the brake caliper (2) | ||
| *BA42.10-P-1003-12J | |||
| 17 | Detach brake hose (7) from brake caliper (2) | When replacing the brake caliper (2) Replace brake hoses | |
Seal connections immediately. To avoid damage through escaping brake fluid. |
AR42.10-P-0013EW | ||
| Figure | |||
| Only carry out steps 18 to 21 when removing/installing the brake disk (9) | |||
| 18 | Remove bolts (11) from wheel carrier (12) and remove brake caliper support (8) | *BA42.10-P-1001-12J | |
| Fig 3 | |||
| 19 | Remove security bolt (13) from rear wheel hub and remove brake disk (9) | If the parking brake drums are run in turn back parking brake adjuster. Otherwise, the parking brake shoes will be damaged. |
|
If the parking brake drums are run in: ↓ |
*BA42.10-P-1001-06H | ||
| Adjust parking brake | AR42.20-P-0540EW | ||
| Clean | |||
| 20 | Clean contact surface and interference fit of brake disk (9) | ||
| 21 | Lightly grease interference fit of brake disk (9) | Paste, hot lubrication 1 kg, DBL 6879.20 | *BR00.45-Z-1005-06A |
| 22 | Install in the reverse order | ||
| 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 the engine, actuate brake pedal several times until pressure is built up and maintained in the brake system. | AS42.50-Z-0002-01A | |
| 23 | Operate the brake pedal several times until the brake pads (6) abut the brake disks (9) | ||
| 24 | Check fluid level in brake fluid reservoir, and correct if necessary | ||
| AP42.10-P-4210EW | |||
| 25 | Carry out brake test on the test stand | ||
| AP42.00-P-4290BA |
BRAKE DISKS, BRAKE COVER PLATE
| Number | Designation | MODEL 207 | MODEL 212 | |
|---|---|---|---|---|
| BA42.10-P-1001-06H | Safety screw, rear axle brake disk to wheel flange | Nm | 10 | 10 |
REAR AXLE BRAKE CALIPER
| Number | Designation | MODEL 212 | MODEL 207 | |
|---|---|---|---|---|
| BA42.10-P-1001-12J | Screw/bolt, brake caliper to hub/rotor assembly | Nm | 115 | 115 |
REAR AXLE BRAKE CALIPER
| Number | Designation | MODEL 212 | MODEL 207 | |
|---|---|---|---|---|
| BA42.10-P-1003-12J | Screw/bolt, brake wear sensor to brake caliper | Nm | 8 | 8 |
REAR AXLE BRAKE CALIPER
| Number | Designation | MODEL 212 | MODEL 207 | |
|---|---|---|---|---|
| BA42.10-P-1004-12J | Guide pin to brake caliper support | Nm | 25 | 25 |
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1005-06A | Paste, hot lubrication 1 kg, DBL 6879.20 | A 000 989 76 51 |
| BR00.45-Z-1028-04A | Assembly cleaner | - |