Removing Front Disc Brake Pads

Information 

• Do not open the brake system. 
• Do not loosen the brake hose from the brake calliper when loosening the brake calliper. 
• The core of the warning contact line must not be exposed! Worn insulation is not important! 
• If necessary, remove a little brake fluid from the reservoir by suction in order to prevent an overflow when the disc brake pads are pushed back. 

1. Screw the two assembly aids (assembly pins) -1-  , instead of two wheel bolts, into the wheel hub before removing/fitting the wheel. During removal, first remove the three remaining wheel bolts and remove the wheel carefully without touching the brake discs.

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   Front-axle brake disc with calliper and assembly aids 1 (threaded bolts for fitting wheel)

2. Then (after removing the wheel), remove the two assembly aids (assembly pins) -1-  again.

   Information 

   • Do not open the brake system. 
   • Do not loosen the brake hose from the brake calliper when loosening the brake calliper. 
   • The core of the warning contact line must not be exposed! Worn insulation is not important! 
   • If necessary, remove a little brake fluid from the reservoir by suction in order to prevent an overflow when the disc brake pads are pushed back. 
3. Partially remove the brake calliper. Check the following while doing this:

   Information 

   • To gain better access for removal of the brake calliper, turn the steering fully either to the right or left. 
   1. 3.1 Remove the holders -1, 2-  for the brake hydraulic lines from the wheel bearing housing -3-  .

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      Mounting for hydraulic lines (shown as an example, brake calliper removed)

   2. 3.2 Pull the brake pad wear indicator line out of the brake calliper.
   3. 3.3 Disconnect plug connection for speed sensor.

   Information 

   Protect the paintwork on the brake calliper from damage using a suitable cloth.

4. Carefully press the brake pads back using water pump pliers. Remove a little brake fluid from the reservoir by suction if necessary in order to prevent an overflow!
5. Use removal/assembly aid for brake callipers > T10439 - assembly pin  .

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   Assembly pin on brake calliper

   Information 

   Never use power tools (impact bolter) for loosening and securing the brake calliper on the wheel bearing housing.

6. Remove top fastening screw on the brake calliper and insert assembly pin -top direction arrow-  .

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   Fastening screws on brake calliper

7. Remove bottom fastening screw on the brake calliper and insert assembly pin -bottom direction arrow-  .

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   Assembly pin for brake calliper fitted

8. Pull the brake calliper as far as required out of installation position until the brake calliper engages in the cut-outs on the assembly pins. Carefully guide the brake line and brake hose along as well!

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   Brake calliper tool fitted

9. Fit the brake piston between the brake pads on the brake calliper using > Nr.144 - piston resetting fixture (replaces P83)  , see Workshop Equipment Manual, Chapter 2.4 and press the pads back evenly -arrows-  . Remove a little brake fluid from the reservoir by suction if necessary in order to prevent an overflow!

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   Pressing back brake pads

10. If you intend to re-use the brake pads, mark the relevant installation position.  Carefully slide a commercially available screwdriver between the brake pad/brake calliper and lever the brake pad out by turning the screwdriver slightly. When doing this, make sure not to damage the dust boots on the brake pistons -arrows-  .

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    Removing brake pads (shown with brake calliper removed for a better view)

11. Remove pad retaining springs.