Checking brake disc thickness

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

1040 - 46

Dismantling and assembling front brake

Dismantling

Note

1. Remove brake caliper (do not disconnect brake hose or brake line / remove brake hose retainer from spring strut).

2. After removing the countersunk head screw(s), take off brake disc. If the brake disc is binding and cannot be freed with light plastic hammer blows, screw two hexagon head bolts evenly into both 8 mm threads of brake disc and press off brake disc.

Be careful not to confuse right-hand and left-hand brake discs on Turbo - Look vehicles during reassembly.

The discs may be identified by their involute shape and part number. The part number is indicated on the brake disc.

Left-hand spare part -

3rd group number: uneven digit

Right-hand spare part -3rd group number: even digit

Example:

Part No. for left-hand brake disc: 965.351.043.00

Assembly

Part No. for right-hand brake disc: 965.351.Q44.00

1. Check condition of all components and replace if required.

2. Clean end face and centering surface of brake disc and wheel hub. Coat centering surface of wheel hub with a thin coat of Optimoly TA.

4. Fit brake caliper. Tighten brake caliper bolts to 85 Nm (63 ftlb.).

Check for correct position of brake hose and brake line.

3. Fit brake disc.

Dismantling and assembling rear brake

Dismantling

1. Remove brake caliper (do not open hydraulic brake system). To do so, remove ground wire and bracket (A) from left-hand rear-axle trailing arm (arrows). Before starting work, extend brake hose retainer (B).

This allows the brake line or brake hose, respectively, to remain sealed when the brake caliper is fitted.

476-D39/45

Note

If the wheel hub must be removed (not required for replacement of parking brake shoes), undo hexagon head nut on drive shaft before removing the brake caliper.

2. Engage a screwdriver into the hose in the brake disc and turn adjuster in the "slackening" direction. Lift off brake disc after removing the countersunk head screw(s).

3. Remove thrust springs (No. 2), adjuster (No. 3/4) and return spring (No. 5). Remove parking brake shoes and return spring (No. 6).

6/03/06

Assembly

1. Apply a thin coat of grease to adjuster (No. 3/4), operating lever pin (spreader lever) and sliding surfaces of parking brake shoes.

2. Install operating lever (spreader lever), brake shoes, return springs, thrust springs and adjuster.

Do It Yourself Car Diagnosis

Do It Yourself Car Diagnosis

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