Models With 15 Inch Wheels
Component Notes and Information
NOTE:
^ During service procedures, refer to the illustration above and the information below
^ After servicing calipers, depress brake pedal firmly several times with vehicle stationary so that the brake pads are properly seated in their normal operating position.
^ To remove brake fluid from the reservoir use a bleeder bottle which is used only for brake fluid
WARNING: Brake fluid is poisonous.
1 Hex bolt
- Always replace each time after removing
- Tightening torque on vehicles with all wheel drive:
- Tighten to: 150 Nm (111 ft lb) and turn 90° further
- All wheel drive vehicles: loosen and tighten only when vehicle is on its wheels (danger of accident)
2 Washer
3 Hex socket head bolt
- Tighten to: 10 Nm (7 ft lb)
4 Brake rotor
- Thickness: 12 mm
- Wear limit: 10 mm
- When worn always replace on both sides
5 Hex bolt
- Tighten to: 10 Nm (7 ft lb)
6 Splash plate
7 Hex bolt
8 Spring
- For brake pressure regulator
- Adjusting brake pressure regulator. Adjustments
- Not installed on vehicles with all wheel drive and Bosch 5.3 ABS
9 Hex nut
- Tighten to: 20 Nm (15 ft lb)
10 Retaining plate
- Mark installation position before removing
11 Bracket
12 Control arm
- Removing and installing, refer to Steering and Suspension
13 Self-locking hex nut
- Tighten to: 200 Nm (148 ft lb)
- Always replace
14 Tensioning disc
- With impulse rotor for ABS speed sensor
15 Speed sensor
16 Hex socket head bolt
- Tighten to: 10 Nm (7 ft lb)
17 Hex bolt
- Tighten to: 170 Nm (125 ft lb)
18 Wheel bearing
19 Circlip
- Ensure correct seating
20 Hub
21 Brake carrier with guide pins and protective cap
- Vehicles up to Chassis No. 70ZWH130 482 or 70ZWX121 939 have no anti-rattle springs
- Supplied as replacement part assembled with guide pin grease
- If protective caps or guide pins are damaged use repair kit.
- Use grease packet supplied in repair kit to lubricate guide pins.
22 Brake pads
- Thickness: 11.5 mm not including backing plate
- Checking thickness: Repair Manual, Maintenance
- Wear limit: 2 mm, not including backing plate (remaining pad thickness)
- Always replace on both sides
- Removing and installing, refer below.
23 Self-locking hex bolt
- Tighten to: 35 Nm (26 ft lb)
- Always replace
- When loosening and tightening counter hold on guide pin
24 Guide pin
25 Protective cap
26 Brake caliper
- Modification: Vehicles from VIN 70ZWH130 483 or 70ZWX121 940, introduction of anti-rattle springs (item 29) and modified brake carrier (item 30)
- Servicing, refer to Overhaul. Service and Repair
27 Parking brake cable
- Adjusting parking brake. Adjustments
28 Spring clip
29 Anti-rattle spring
- Installed in vehicles from Chassis No. 70ZWH130 483 or 70ZWX121 940
- Install in conjunction with new brake carrier (item 30) only
- Always replace when changing pads
30 Brake carrier with guide pins and protective cap
- Installed in vehicles from VIN 70ZWH130 483 or 70ZWX121 940 with introduction of anti-rattle springs (item 29)
- Supplied as replacement part assembled with guide pin grease
- If protective caps or guide pins are damaged use repair kit.
- Use grease packet supplied in repair kit to lubricate guide pins.
NOTE: If reusing brake pads mark and return to same location.
Removal
- Remove wheels.
- Remove parking brake cable from brake caliper.
- Remove securing bolts (arrows) for brake caliper housing .
- Remove brake caliper housing and lay to one side so that weight of brake caliper does not stress or damage brake hose.
- Remove brake pads.
- Install anti-rattle springs, if part of original equipment.
Installation
WARNING: Brake fluid is poisonous.
NOTE:
^ Before pressing the piston back, remove some brake fluid from the reservoir.
^ Use a bleeder bottle or a plastic bottle which is only used for brake fluid.
- Hang brake caliper housing on hook (arrow B).
- Screw in brake caliper piston by turning knurled wheel of special tool 3272 clockwise.
NOTE:
^ Do not damage the protective cap when turning in the brake caliper piston.
^ Position special tool 3272 so that the collar (arrow) of the tool is seated on the brake caliper.
^ If the piston is difficult to move, use a 13 mm open end wrench on the flats (arrow A) provided for this purpose.
^ If the piston is pushed back with a piston resetting tool or by operating the foot brake the automatic adjustment in the brake caliper will be destroyed.
For Vehicles Up To VIN 70ZWH130 482 Or 70ZWX121 939
- Thoroughly clean contact surfaces for brake pads on brake carrier and remove corrosion.
- Install brake pads into brake carrier.
- Measure clearance between brake pads -1- and contact surfaces on brake carrier -2- with feeler gauge -A-.
Clearance: Minimum 0.4 mm (0.016 inch)
- If the clearance is less than 0.4 mm (0.016 in.):
Clean contact surfaces for brake pads on brake carrier again.
Re-measure clearance between brake pads and contact surfaces on brake carrier.
- Remove brake pads.
- Grease contact surfaces for brake pads lightly with grease G 000 650, or equivalent.
- Install brake pads into brake carrier.
For Vehicles From VIN 70ZWH 130 483 Or 70ZWX121 940
- Thoroughly clean contact surfaces for anti-rattle springs on brake carrier and remove corrosion.
- Insert brake pads and anti-rattle springs into brake carrier.
- Measure clearance between brake pads -1- and anti-rattle springs on brake carrier -2- with feeler gauges -A,
Clearance: Minimum 0.4 mm (0.016 inch)
- If the clearance is less than 0.4 mm (0.016 inch):
Clean contact surfaces for anti-rattle springs on brake carrier again.
Re-measure clearance between brake pads and anti-rattle springs on brake carrier.
Install brake pads into brake carrier.
Continued For All Vehicles
- Secure brake caliper housing with new self-locking bolts.
NOTE: The repair kit includes four self-locking hex bolts which must installed.
- Attach parking brake cable (arrow) to brake caliper housing.
- Adjust parking brake. Adjustments
NOTE: Only depress the brake pedal after first adjusting the parking brake.
- Install wheels.
NOTE:
^ After each brake pad change firmly depress the brake pedal several times with the vehicle stationary so that the brake pads are properly seated in their normal operating position.
^ After changing brake pads check the brake fluid level.