Replacement

Make sure that the two brake calipers on an axle are both of the same pattern.

No.

Description

Qty.

Note When: Removing Installing

Special Instructions

1

Lock

1

Replace if necessary

New models have lock wire with wire guide

2

Retaining pin

2

Replace if necessary

3

Cross spring

1

Replace if necessary

4

Inner brake pad

1

Check, replacing if necessary. Wear limit: 2 mm. It is better to mount pad after installation of brake caliper

5

Warning contact

1

Replace if wire core is ground through

6

Outer brake pad

1

Check, replacing if necessary. Wear limit: 2 mm. It is better to mount pad after installation of brake caliper

7

Mounting frame

1

Position slides correctly

8

Brake cylinder

1

Drive off of floating frame with plastic hammer. Place piece of wood in caliper frame

9

Floating frame

1

10 11

Guide spring Clamp

1 1

Don't mix up left and right springs Position correctly

12

Dust cap

1

Replace

13

Piston

1

Press out of cylinder with compressed air. Support piston on piece of wood. Danger!

Use brake cylinder paste. Adjust piston position with 20° gauge

No.

Description

Qty.

Note When Removing

Installing

Special Instructions

14

Seal

1

Remove with a plastic rod

Replace, install with brake cylinder paste

15

Dust cap

1

16

Bleeder screw

1

17

Slide

2

Replace, if necessary

DISASSEMBLING AND ASSEMBLING FLOATING FRAME CALIPER

Disassembling

1. Press caliper frame off of mounting frame.

3. Press piston out of cylinder with compressed air.

Warning

Support piston on piece of wood.

2. Drive brake cylinder off of caliper frame with a plastic hammer applied at different points all around. Place a piece of wood in caliper 4. Remove seal with a plastic rod.

frame to prevent damage.

Assembling

1. Apply a very thin coat of brake cylinder paste to cylinder bore, piston and seal. Press piston into cylinder in approximately correct position (20 chamfer).

3. Install mounting frame. Be careful not to damage slides.

2. Drive brake cylinder with guide spring on to 4. Make final 20° adjustment of piston with piston caliper frame with a soft mandrel applied at turning pliers (see page 46 - 4).

points all around.

Brake hose installation changed during 1983 model year. Brake hose mounted on modified fist caliper connection with a hollow union bolt from this time on to guarantee correct installed position.

No.

Description

Qty.

Note When: Removing Installing

Special Instructions

1

Housing retaining spring

1

Replace, if necessary. Make sure of correct fit

2

Plug

2

Replace, if necessary

3

Guide pin

2

Replace, if necessary. Tighten to specified torque

(15-20 Nm/ 11 - 14 ftlb)

4

Housing (caliper)

1

Note 20° piston position. If necessary, correct with piston pliers. Set back (milled) surface faces down to brake disc inlet side. Reference point is edge on bottom of housing (page 47-11)

5

Brake pad, inner {with riveted retaining clip)

1

Pull out of piston

Check, replacing if necessary. Wear limit 2 mm

6

Brake pad, outer

1

Check, replacing if necessary. Wear limit 2 mm

7

Holder

1

8

Piston

1

Press out of housing with compressed air. Use piece of wood -danger!

Use brake cyl. paste. Watch 20° piston position

g

Dust cover

1

Replace; make sure sealing lips fit correctly in housing and piston groove. See instructions

No.

Description

Qty.

Removing

Note When: Installing

Special Instructions

10

Seal

1

Remove with a plastic rod

Replace, install with brake cylinder paste

11

Dust cap

1

12

Bleeder valve

1

13

Damper sleeve

2

Replace when torn, brittle or swollen rubber

Page 47-12

14

Slide

2

Replace if necessary

Page 47-12

DISASSEMBLING AND ASSEMBLING FLOATING CALIPER

Disassembling

1. Remove housing retaining spring. Pull plugs out of guides. Remove guide pins.

2. Remove housing. Take outer brake pad off of holder. Pull inner brake pad out of piston.

3. Support piston firmly on a piece of wood and press out of housing with compressed air. Press out piston only halfway at first and take sealing lip of dust cover out of piston groove.

4. Remove seal with a plastic needle.

2. Push dust cover on inside of piston so far that large diameter sealing lip (arrow) extends over the piston.

3. Press sealing lip of dust cover into housing groove with piston in approximately correct position (20° set back surface). Make sure that seal fits properly around its entire periphery.

Assembling

1. Apply a very thin coat of brake cylinder paste on cylinder bore, piston and seal.

4. Press piston into housing slowly. Small diameter sealing lip should settle in groove of piston.

5. Adjust 20° piston position precisely with the piston pliers. Set back surface of piston faces down to brake disc inlet side. A reference point is the edge on bottom of housing (see arrow). Arrow a = brake disc inlet side.

6. Replace damaged dampers and guides.

7. Bolt holder to housing. Tighten guide pins to specified torque. Insert brake pads and housing retaining springs.

REPLACING DAMPERS AND SLIDES

Removing

1. Separate housing from holder. Pull piston end brake pad out of piston,

2. Press out damper in direction of brake hose connection. Make sure that bearing surface in housing is not damaged.

Installing

1. Coat damper with brake cylinder paste.

2. Insert damper in housing from the brake hose connection side. Then guide slide from piston side into damper so far, that it is positioned between the lips provided for this purpose (arrow = visible lip).

REMOVING AND INSTALLING BRAKE MASTER CYLINDER

Removing

1. Remove intake hoses and air cleaner upper section.

2. Drain both chambers of brake fluid reservoir by pumping out brake fluid via pertinent bleeder screws depending on brake circuit division.

Diagonal brake circuit division up to 1983 models. Axle brake circuit division since 1984 models.

Identification: stepped master cylinder and screw-in brake pressure regulator (see point 5).

5. Detach brake lines. Up to 1983 models,

Counterhold on hexagon of regulator when unscrewing rear axle brake line on screw-in brake pressure regulator. Screw-in regulator of cars with ABS is installed on hydraulic unit.

4. Pull brake fluid reservoir out of master cylinder from above. If applicable, pull off plugs on hydraulic stop light switches.

3. Detach vacuum hose with check valve at brake booster.

Pull off vacuum line on branch, plug for warning device and hose for clutch control.

4. Pull brake fluid reservoir out of master cylinder from above. If applicable, pull off plugs on hydraulic stop light switches.

Since 1984 models

Counterhold on hexagon of regulator when unscrewing rear axle brake line on screw-in brake pressure regulator. Screw-in regulator of cars with ABS is installed on hydraulic unit.

6. Remove the master brake cylinder at its flange with a 1/4-inch ratchet, a 13 mm socket wrench insert and a suitable extension. Take out the master brake cylinder.

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