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.
^ . New brake calipers are filled with brake fluid and pre-bled.
^ Apply a thin coat of assembly lubricant G 052 150 A2, or equivalent, to brake cylinders, pistons and seals.
^ . When repairing, it is essential to appropriately pre-bleed the brake calipers (without brake pads) before installation in the vehicle. Service and Repair

1 Self-locking bolts
- Tighten to: 35 Nm (26 ft lb)
- Always replace
- When loosening and tightening counter-hold on guide pin
2 Seal
- Removing and installing, refer below
3 Piston with automatic adjustment
- Removing and installing, refer below
4 Protective seal
- Pull outer sealing lip onto piston
5 Dust cap
6 Bleed valve
7 Brake caliper housing with parking brake cable lever
- If a leak exists at parking brake cable lever replace brake caliper housing
- After servicing, pre-bleed caliper housing. Service and Repair
8 Guide pin
- Grease before pulling on protective cap
9 Protective cap
- Pull onto brake carrier and guide pin
10 Brake carrier With guide pin, and protective cap
- Supplied as replacement part, assembled with guide pin grease
- If protective caps or guide pins are damaged, install repair kit
- Use grease packet supplied in repair kit to lubricate guide pins

Special Tools





- 3272 Resetting and removal tool





- 3409 Wedge
- Bleeder container

Removal





- Screw piston out of brake caliper housing by turning knurled wheel counter-clockwise.

NOTE:
^ Do not damage the protective seal when removing the piston.
^ Position special tool 3272 so that the collar (arrow) is in front of the piston.
^ If the piston is difficult to move, use a 13 mm open end wrench on the flats (arrow A) provided for this purpose.
^ The surfaces of the piston and the seal must only be cleaned with methylated spirits and then dried.





- Remove seal using wedge 3409.

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.





- Screw piston into housing by turning knurled wheel clockwise.

NOTE:
^ Do not damage the protective seal when installing the piston.
^ Position special tool 3272 so that the collar (arrow) of the to9l 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 is destroyed.

- Install brake pads.