Remove/Install Front Axle Brake Caliper Guide - Ar42.10-D-0401TS

Model 907 

Shown on model 907 with code IT5 (5.0 tons), left side of vehicle 

	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
	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
	Brake fluid notes		AH42.50-P-0001-01A
	Notes on repairs to brake system		AH42.00-P-0003-01A
	Remove
1	Remove brakepads (8).		AR42.10-D-1610TS
2	Remove respective brake caliper (3).	Do not detach brake hose. Dispose of dust caps (1) and bolts (2).	AR42.10-D-0070TS
3	Remove anti-rattle springs (9) from brake caliper support.	Dispose of anti-rattle springs (9).
4	Remove guide pins (5, 6) and boots (7).	Firstly push guide pins (5, 6) out of guide in direction of brake disk; then remove boots (7). Dispose of guide pins (5, 6) and boots (7).
	Clean
5	Clean contact surfaces on brake caliper support.	Brake caliper brush	Fig 1
6	Clean dust cap seat and coat with lubricating grease from repair kit.
7	Clean seats of guide pins (5, 6).	Assembly cleaner	*BR00.45-Z-1028-04A
	Check
8	Check brakepads (8) for damage and wear.
	Assess condition of brake linings	If corresponding findings are present, ↓	AP42.10-D-4252TS
		Replace brakepad (8) on front axle.
9	Check brake disk for damage and wear.
	Assess condition of brake disks	If corresponding findings are present, ↓ replace front axle brake disks.	AP42.10-D-4256TS
		Remove/install front axle brake disk	AR42.10-D-0230TS
10	Check brake caliper (3) for damage and leakage.	If the brake caliper (3) is damaged or leaking or a boot of a brake piston is damaged, ↓ replace brake caliper (3). Remove/install front axle brake caliper	AR42.10-D-0070TS
	Install
11	Coat new guide pins (5, 6), new boots (7) and guide bores in the brake caliper (3) with lubricating grease from repair kit.
12	Install boots (7) in grooves on brake caliper (3) from brake disk side.	Make sure that the boots (7) are seated correctly in the grooves on the brake caliper (3). Otherwise, the brake caliper (3) can no longer move freely.
13	Install guide pins (5, 6).	Ensure that the boots (7) are seated correctly in grooves of guide pins (5, 6). Otherwise, the brake caliper (3) can no longer move freely. Install guide pin (5) with guide ring (4) in upper guide bore and guide pin (6) in lower guide bore. Push each of the guide pins (5, 6) into each guide bore from outside in direction of brake disk. Remove excess lubricating grease.
14	Allow existing air to escape from the boots (7).	Make sure that the boots (7) are correctly seated on the brake caliper (3). Otherwise, malfunction or damage can occur. For this, lift respective boot (7) at one point a little out of the groove of the respective guide pin (5, 6) and allow air to escape.
15	Install new anti-rattle springs (9) on brake caliper support.
16	Install brake caliper (3).	Use new dust caps (1) and bolts (2).	AR42.10-D-0070TS
17	Install brakepads (8).	If the brakepads (8) are reused, ↓ install brakepads (8) at previous positions.	AR42.10-D-1610TS
18	Build up brake pressure by fully depressing brake pedal several times.
19	Check fill level in brake fluid reservoir.	If the brakepads (8) have been replaced.
	Brake system - inspect fluid level	If the fill level is incorrect, ↓ correct fill level.	AP42.10-D-4210TS
		Brake fluids (DOT 4 plus) Commercially available devices/tools  Extraction bellows	BB00.40-P-0331-00A
	Check
	Risk of accident  from vehicle starting off by itself when engine running. Risk of injury  (bruises and burns) resulting from working on the engine while it is being started or when it is running.	Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A
20	Check brake system for leaks.		AR42.10-D-0100-01TS
21	Perform brake test.
	Brake test		AP42.00-D-4290TS

Fig 1: Brake Caliper Brush (000 589 26 68 00)