Notes On Repairs To Brake System - AH42.00-N-0003-01KOA

Model all 

1. When performing maintenance and repair work on the brake system, it must be ensured that no mineral oil, lubricating grease or similar substances enter the brake system.
2. New brake fluid must be used as a flushing and cleaning agent for the cylinders, the lines and the expansion reservoir of the hydraulic braking system.
3. If mineral oil is found in the brake system, or if the presence of mineral oil in the brake system is suspected, the procedure below must be followed:
   1. 3.1 Replace the tandem master brake cylinder or hydraulic unit and the expansion reservoir for the brake fluid.
   2. 3.2 Thoroughly flush the entire brake system with new brake fluid.
   3. 3.3 All brake components with parts made of rubber, such as brake calipers, brake hoses, the SBC™, ABS, ETS, ASR or ESP hydraulic unit, pressure reservoir, charging piston unit and charging pump, which may have come into contact with mineral oil, must be replaced.
   4. 3.4 Bleed brake system.

Handling SBC™, ABS, ETS, ASR and ESP parts from accident vehicles: 

If, because of the extent of the damage to the vehicle or the position and external appearance of the hydraulic unit, it is obvious that the hydraulic unit has sustained a severe shock, the hydraulic unit must be replaced.

A damaged hydraulic unit can lead to brake power failure.

Indications of this are e.g.:

• Hydraulic lines kinked.
• Connections to hydraulic unit leaky.
• Electrical lines or plug couplings damaged.
• Metal block of hydraulic unit exhibits signs of damage.
• Hydraulic unit has jumped out of bracket and cannot be fitted back in without applying excessive force.

If this does not apply, the system must be subjected to a rigorous function test and the test steps for the solenoid valves and pump must be performed.

A damaged brake system can lead to brake power failure.

Brake caliper may: 

• Not  be scratched, and the paint on painted brake calipers may not be damaged.
• Not  be removed/installed with hammers, levers, pliers or other tools.
• Not  be machined.
• Not  be put down on the painted visible side.
• only  be put down on a clean surface.

Particular caution must be exercised for the following activities.

Otherwise, the brake calipers may be damaged.

• Removal/installation of complete wheels.
• Removal/installation of brake linings.
• Removal/installation of brake calipers.
• All work in the area of the wheel well, e.g. removal/installation of suspension struts, transverse control arms, stabilizer bars, etc.
• Lowering of vehicle with detached complete wheels.

Painted brake calipers are especially sensitive.