Checking brake disc thickness

Measure brake disc thickness in approx. 8 places within the braking surface using a micrometer.

DISASSEMBLING AND ASSEMBLING PARKING BRAKE LEVER

No.

Description

Qty.

Note When: Removing Installing

Special Instructions

1

25 Nm (18 ftlb)

2

Lock washer

2

Replace if necessary

2a

Washer

1

Only used in some cases

Sometimes a washer is used to align parking brake lever

3

Bracket for parking brake switch

1

Switch must respond before first catch; align bracket if necessary

4

Parking brake lever

1

5

Sleeve

1

Paste on sides

6

Lock nut

23 Nm (17 ftlb)

7

Bearing shaft

1

8

Toothed element

1

9

Push button

1

Lock with Loctite 221

10

Plastic washer

1

11

Spring

1

12

Push rod

1

13

Guide sleeve

1

14

Rivet

1

Rivet that pawl still moves easily

15

Pawl

1

16

Stop

1

DISASSEMBLING AND ASSEMBLING PARKING BRAKE LEVER

Disassembling

1. Remove parking brake lever/parking brake cable trim. Unscrew mounting bolts and take out complete parking brake lever.

2. Pull off sleeve forward from parking brake lever (pasted on sides of lever - loosen first).

3. Remove bearing shaft and move out locking element.

4. Unscrew push button (locked with Loctite). Take off washer, spring and guide sleeve toward front and push rod toward rear.

Assembling

1. Lubricate all sliding and bearing surfaces with multi-purpose grease.

2. Pawl must move easily even after riveting. Lock push button with Loctite No. 221.

3. Install parking brake lever and check function of contact switch. It should respind before the first catch. If necessary, adjust switch holding bracket.

Checking and Adjusting Parking Brake

The parking brake has to be adjusted, if with medium force the parking brake lever can be pulled up more than 2 teeth without any braking effect.

1. Jack up car and remove rear wheels.

2. Release parking brake and push back rear wheel disc brake pads until the discs can be turned easily.

3. Loosen adjusting nut on spreader lock until cable is without tension.

4. Insert a screwdriver through the hole in the brake disk and turn the adjusting device until it is no longer possr ble to turn the wheel. Then turn back the adjusting device until it is possible to turn the wheel freely, then turn back a further 2 notches (undo).

5. Pull up parking brake lever 2 teeth and turn adjusting nut that the wheels can just be turned by hand (with 4 teeth the wheels must be stopped).

6. Release parking brake lever and check, whether wheels turn easily.

7. Lock adjusting nuts.

TIGHTENING TORQUES FOR BRAKES, HYDRAULIC PARTS

Location

Description

Thread

Torque Nm (ftlb)

Brake unit to bulkhead

Hex nut

DIN 934

23 (17)

Brake 1ine to master cylinder, brake hoses, brake booster, T-dis-tributor and hydraulic unit. Connecting line to four-piston fixed caliper

Union nut

M 10 x 1

12 (9)

Brake hoses to sliding caliper

Brake hose

M 10 x 1

14 (10)

Brake hose to floating caliper

Brake hose

M 10 x 1

14 (10)

Brake hose to floating and four-piston fixed calipers

Hollow screw

M 10 x 1

16.5 (13)

Brake hose, rear, to four-piston fixed caliper

Brake hose

M 10 x 1

14 (10)

Locknut to pressure rod (brake unit)

Hex nut

M 10 DIN 934

35 (26)

Bleeder screws in sliding and floating calipers

Bleeder screw

M 7

3.5 to 5.0 (2.5 to 3.6)

Bleeder screw in four-piston fixed caliper

Bleeder screw

M 10

8-12 (6 - 9)

Location

Description

Thread

Torque Nm (ftlb)

Master cylinder to vacuum booster

Hex nut

DIN 934

23 (17)

Stoplamp switch to master cylinder

Stoplamp switch

M 10 x 1 tapered

15+4 (11 + 3)

Regulator to wheel arch

Hex bolt

M 8

23 (17)

Screw-in regulator to master cylinder or hydraulic unit

Screw-in regulator

M 10 x 1

14 (10)

Hydraulic unit bracket to wheel arch

Hex nut

M 8

23 (17)

Hydraulic unit to hydraulic unit bracket

Hex bolt

M 6

10 (7)

T-distributor to bracket

Hex bolt

M 6

10 (7)

Housing (caliper) to bracket

Guide pin

M 9

15 - 20 (11 - 15)

0 0

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