Overhaul

Component Notes and Information

NOTE:
^ During service procedures, refer to the illustration above and the information below
^ When repairing install all parts supplied in the repair kit.
^ Apply a thin coat of assembly lubricant G 052 150 A2, or equivalent, to brake cylinders, pistons and seals.

1 Protective cap
- Push onto bleed valve
- Secures brake pad wear indicator wiring
2 Bleed valve
- Apply thin coat of assembly lubricant G 052 150 A2, or equivalent, to threads before installing
3 Cap
- Insert in mounting bushing
4 Guide pin
- Tighten to: 25 Nm (18 ft lb)
5 Mounting bushing
- Insert into brake caliper housing
6 Brake caliper housing
7 Brake carrier
- Install on brake caliper housing
8 Retaining spring
- Insert with both ends in holes in brake caliper housing
9 Seal
- Removing and installing, refer below
10 Piston
- Removing and installing, refer below
11 Protective seal
- Do not damage when installing piston

Special Tools





- 3409 Wedge
- Piston resetting tool

Removal





- Force piston out of brake caliper housing using compressed air.

NOTE: Place a piece of wood in the recess to prevent damaging the piston.





- Remove seal using wedge 3409.

NOTE:
^ When removing the seal make sure that the surface of the cylinder is not damaged.
^ The surfaces of the piston and the seal must only be cleaned with methylated spirits and then dried.

Installation
- Thinly coat piston and seal with assembly lubricant G 052 150 A2 before installing.





- Place protective seal with outer sealing lip on piston.





- Using wedge 3409, insert inner sealing lip into cylinder groove.

NOTE: Hold piston in front of caliper housing while inserting sealing lip.






- Press piston into brake caliper housing using piston resetting tool.

NOTE: The protective seal outer sealing lip will then locate in the piston groove.