...................................................................................... A..

EXIT

rakes, hydraulic and mechanical 42

 EXIT

42 rakes, hydraulic and mechanical

Job No.

Brake system
Bleedrng the brake system or renewing the brake fluid ................. , ... 42-010
Checking the brake lanes and brake hoses ............................. ...... 012
Checking the brake system for leaks .................................. ...... 015
Checking warntng devrce In expansion tank ............................... ...... 035
Checktng and adjusting or removal and installatron of mechanical stop lamp switch ....... 040
A. Stop lamp switch 1 st version ......... ........
B. Stop lamp switch 2nd version ................

Brake caliper
Removal and Installation of floating caliper on front axle . . . . . . . . . . 110
Removal and Installation of fixed caliper on rear axle .... ....... . . . . 120
Replacing brake pads ........................ ..... . . 160
A. Fixed caliper .......................... .......
8. Floating caliper ............................ .......

Brake disk
Removal and rnstallation of brake disk on front axle ..... ....... ......... . . . 220
Removal and tnstallatron of brake disk on rear axle ...... ........ .......... . . . . 228
Cleaning of brake disks ........................... ....... .......... . . . 260

Stepped tandem master cylinder

Removal and rnstallatron of stepped tandem main cylinder . . . . 310
Dtsassembly, c h e c k u p a n d a s s e m b l y o f s t e p p e d t a n d e m main cylinder . . . . .... 315

Parking brake
Removal and rnstallatron of parking brake lever . . . . . . . . . . . . . . 510
Removal and rnstallatron of front brake cable control . . . . . . . . . . . . . 520
Removal and rnstallatron of rear brake cable control . . . . . . . . . 525
Removal and rnstallatron of brake shoes of parking brake . . . . . 530
Readjustment of brake shoes of parking brake , . . . . . . . . . . . . 540

42/l
 EXIT

42-005 General information

The tandem main cylinder with central valve is made of light alloy and has no stop screw.

Girling tandem main cylinder

1 Tank plug
O-ring
: Prston (pushrod crrcuit) 22 1 D 20 1 B C 4 6 7
4 Stop washer
Locking ring
; Secondary sleeve
7 Bushing
Stop washer
: Filling disk
10 Primary sleeve
11 Supporting ring
17 Compression spring
Separating sleeve
:: Piston (floating circuit)
21 Compression spring
22 Housrng
24 Valve spring
25 Valve seal
27 Cyl. pin
28 Valve pin
Fillrng bore
: Compensating bore
D Frllrng and compensating bore

Bendix tandem main cylinder

Tank plug
5
4
Piston (pushrod circuit)
Stop washer
Locking ring
: Secondary sleeve
7 Bushing
9 Filling disk
10 Primary sleeve
11 Supporting ring
17 Compression spring
18 Separating sleeve
20 Piston (floating circuit)
21 Compression spring
22 Housing
24 Valve spring
25 Valve seal
27 Cyl. pin
28 Valve pin
B Filling bore
C Compensating bore
D Filling and compensating bore

42.6-005/l F 2
 EXIT

Teves tandem main cylinder

1 Tank plug
2 O-ring
3 Piston (pushrod circuit) 21 22 1 D 20 1 6 C 9 6 7 TJ
4 Stop washer
5 Locking ring
6 Secondary sleeve
7 Bushing
8 Stop washer
9 Filling disk
10 Primary sleeve
11 Supporting ring
17 Compression spring
18 Separating sleeve
20 Piston (floating circuit)
21 Compression spring
22 Housing
24 Valve spring
25 Valve seal
27 Cyl. pin
28 Valve pin
B Filling bore
C Compensating bore
D Filling and compensating bore

42.6~00512 F 2
 EXIT

42-010 Bleeding the brake system or renewing the brake fluid

Brake fluid

Use specified brake fluid only refer to Specifications for service products,
page 331 .O

Important note

Handle brake fluid with care

a) Fill brake fluid only into container from which the fluid cannot be consumed by mistake.
( Fatal dose 100 cc).

b) Even slight traces of mineral oil will lead to failure of brake system. When brake fluid looks from colorless up
to yellow, particular attention is required since in such a case the risk of making a mistake is the highest. If
mineral oil is found in brake system or if the presence of mineral oil is suspected, thoroughly flush entire brake
system with brake fluid. Also renew main cylinder.

c) Brake fluid is highly hygroscopic, that is, it will absorb moisture out of the air, which in turn will lower the
boiling point. For this reason, store brake fluid in well sealed storage tanks only.

Note: During its service life, the boiling point of the brake fluid will go down as a result of constant absorp-
tion of moisture from the atmosphere. When the brakes are very sharply applied, there is a possibility of vapor
lock in brake system.For this reason, change the brake fluid once a year, if possible, in spring.

To facilitate inspections, a new sticker naming the year and month of the next fluid change must be glued to
brake unit during each change of fluid.

42.6-010/l
 EXIT

Bleeding

1 When using a bleeding unit, observe operating instructions of pertinent manufacturer.

To remove all air bubbles from tandem main cylinder, be sure to step down fully on brake pedal at least three
times while bleeding, with bleed screws of brake pedal opened.

2 When bleeding by pumping the brake pedal, close the respective bleeder plug each time prior to releasing
the brake pedal, so that no air will enter through the threads of the bleeder plug.

Note: Slowly retract brake pedal, so that enough brake fluid is drawn from expansion tank during piston return
stroke.

3 Stop bleeding when clear brake fluid, free of bubbles, emerges from bleed hose.

Attention!
Do not use the pumped out brake fluid again, since it may contain foreign bodies which will then again enter the
brake system.

4 Fill expansion tank with brake fluid up to maximum mark.

Renewing

5 Pump empty or draw fluid out of expansion tank down to a fluid level of approx. 10 mm.

Attention!
Do not empty expansion tank completely, so that no air can enter the brake system.

Renewing the brake fluid with bleeding unit:

Permit approx. 80 cc of brake fluid to flow out at each brake caliper, so that the lines and the pressure cylinders
of the brake calipers will also be filled with fresh brake fluid.

Renewing the brake fluid without bleeding unit:

Fill expansion tank with fresh brake fluid up to maximum mark. Pump old brake fluid of each brake
caliper with approx. 10 pump strokes. Top up brake fluid.

Note: For both methods of renewing brake fluid, the brake fluid flowing out through vent hose must be free of
bubbles.

4 2 . 6 - 0 1 O/2
 EXIT

42-012 Checking brake lines and brake hoses

Check brake hoses and brake lines for chafing marks or other damage e.g. caused by corrosion or road metal. Do
not use steel brush, emery cloth, scrapers or similar sharp-edged tools, since otherwise the plastic layer will be
damaged. Clean dirty brake lines only within scope of an underfloor wash. Do not clean brake hoses with clean-
ing compounds containing mineral oil. Remove outside dirt with water. To prevent spraying or preservating com-
pounds containing mineral oil from coming into contact with brake hoses, cover brake hoses prior to repeating
preservation.

When installing a new brake hose, observe the following:

Install approved brake hoses only.

Do not install brake hose in twisted condition. Twisted brake hoses can be straightened by adjusting the hexa-
gon head on the brake hose within the double hexagon of the safety plate.

Also install brake hose in such a manner that any possibility of chafing is eliminated. To check, turn steering
gear each time completely to righthand and lefthand lock, making sure that each front axle half completes a
full up and down stroke. Also check layout of brake hose on rear wheel brake in uppermost and lowermost
position of spring link.

Attention!
Upon completion of repairs following an accident be sure to check installation of brake hose, since even a minor
change of location of holder on frame floor may change the brake hose layout in such a manner that chafing of
hose will result.

42.6-012/l F 3
 EXIT

42-015 Checking the brake system for leaks

Data

High-pressure test Low-pressure test

_____~ p--
Line test pressure in bar gauge pressure 50-90 3

Duration of test in min. 5 2

- _____~ - - - -
Pressure drop of preset value in % 5 0

Special tool

I 000 589 18 31 00

Conventional tool

e.g. Teves, D-6000 Frankfurt/M.

Pressure tester
Order No. 3.9305- 1020.4/O 1

Note

The leak test required for both brake circuits includes

a high-pressure test and a low-pressure test.

Attention!
In the event of a loss of brake fluid, which cannot be
observed visually, check whether brake fluid has
entered the brake booster through a leaking secon-
dary seal in tandem main cylinder. If so, proceed as
follows:

Do not remove brake booster.

Draw off brake fluid.

Change brake booster if there are more than

100 cc of brake fluid in unit.

42.6-015/l F 3
 EXIT

Note: The flexible diaphragm is resistant to brake

fluid, while the reaction disk and the plate valve in
control member are not. For this reason, draw off
brake fluid only with the brake booster installed.
With the brake booster installed, no brake fluid can
reach the reaction disk or the plate valve up to
100 cc.

Ii igh-pressu re test

1 Connect pressure tester (051) to a brake caliper.

For this purpose, screw bleeder plug out and screw
connection (052) in. Then bleed pressure tester.

2 Run engine at medium speed and establish highest

possible vacuum by suddenly releasing accelerator
pedal.

3 Depress brake pedal with brake pedal winch until

the highest possible line pressure between 50 and 90
bar gauge pressure is obtained, then hold brake pedal
in this position.

4 During the 5 minutes test period, the pressure loss

should not exceed 5 % of the value set. If the pressure
drop is higher, look for leaks and seal.

Low-pressure test

5 Stop engine. Actuate brake pedal until vacuum

is exhausted.

6 Set brake pedal winch to a line pressure of approx.

3 bar gauge pressure.

7 The pressure should not drop during a test period

of 2 minutes. If a pressure loss is indicated, look for
leak and seal.

42.6-01512 F 3
 EXIT

42-035 Checking warning device in expansion tank

Note

The warning lamp in instrument cluster is a combina-

tion lamp, that is, it will light up when:

a) the parking brake is actuated,

b) the brake fluid in one of the chambers in expansion

tank is too low.

Checking

Push both contacts (refer to arrow) down one after

the other. This will close the contact and the warning
lamp should light up. The contact elements cannot
be removed.

42.6-035/l
 EXIT

42-840 Checking and adjusting or removal and installation of mechanical stop lamp switch

A. Stop lamp switch 1st version

Checking

1 The stop lamp should light up at a pedal travel

between 3-20 mm, measured to center of pedal
plate.

Brake pedal
2 Fork head
3 Hex. nut
4 Stop lamp switch
6 Contact button
Holder with flange bolt
: Lock
15 Carrier for brake pedal 1423-10949

Adjusting

2 Adjust stop lamp switch with the two hex. nuts

(3), which are simultaneously serving to attach switch
(4).

42.6-04011 F 3
 EXIT

B. Stop lamp switch 2nd version

1423-14822 \ I
4b

Lock (4b) of stop lamp switch . . . . . . . . . . . . . . . . . Push

Stop lamp switch (4) . . , , . . . . . . . . . . . . . . . . . . . Rotate and pull out
Actuating pin (4a) . . . . . . . . . , . . . . . . . . . . . . . . . Pull out up to stop. This will provide max. distance
,I
a
Brake pedal(1) . . . . . . , . . . . . . . . . , . . , . . . . . . . itep down on pedal. Insert switch and turn until
lock (4b) engages. Then release brake pedal.
Note: The actuating distance is set automatically.

42.6-040/2 F 3
 EXIT

42-l 10 Removal and installation of floating caliper on front axle

Data

23 18

al=--
a Disk contact width 1424 -10910
18 Brake pad
20 Cylinder housing
21 Brake carrier
23 Sliding bolt

Tightening torque Nm

Self-locking hex. head screw for attaching

115
floating caliper to steering knuckle

Conventional tool

e.g. Hazet, D-5630 Remscheid

Open double-box wrench 9 x 11
order no. 612

Note

For loosening and tightening brake lines use conven-

tional double-box wrench only.

Removal

1 Pump brake fluid out of front brake circuit

through an opened vent screw.

Brake hose layout 1st version

42.6-l 10/l F3
 EXIT

2 L .oosen brake hose (30 1) on brake line, then close

brak e hose and brake line immediately with rubber
Pb3

Brake hose layout 2nd version

3 Lift the two holding lugs located laterally on cover

of plug connection by means of a screw driver and
open cover. 00 not use force. Remove cable of clip
sensor (25) from plug connection (26) on floating
caliper. Do not pull on cable.

4 Loosen plug connection (26) of brake lining wear

indicator and brake hose (30) from cylinder housing
(20). Close connection of brake hose and on cylinder
housing with rubber plug.

5 Unscrew hex. head screws (3) on brake carrier (21

Then remove floating caliper from steering knuckle
(33).

Installation

Attention!
When installing a new floating caliper, note the
following: different disk contact width for solid and
vented brake disks.

The piston dia. of the floating calipers of one axle

must be the same. Floating calipers of different
manufacturers may be installed on one and the
same axle.

?42-11023

42.6-l 10/2 F3
 EXIT

25 26

20

a
3
10
21

.33

-33

- 5

Layout with solid brake disk Layout with vented brake disk

3 Self-locking hex. head screw 10 Front wheel hub 3 Self-locking hex. head screw 20 Cyl. houslng
5 Cover plate 20 Cyl. housing 5 Cover plate 21 Brake carrier
6 Brake disk 21 Brake carrier 6 Brake disk 25 Clip sensor
8 Lock screw 33 Steering knuckle 8 Lock screw 26 Plug connection
9 Dowel sleeve 9 Dowel sleeve 33 Steering knuckle
10 Front wheel hub

6 Attach floating caliper with new self-locking hex.

head screws (3) to steering knuckle (6). Pay attention
to perfect installation of brake hose.

Tighten hex. head screws to 115 Nm.

Note: Use self-locking hex. head screws only once.

If the screw-in torque of the new self-locking hex.

head screws is very high, clean threads in floating
caliper by means of a tap M 12 x 1.5 from residual
glue of micro-encapsuilated screws.

7 Attach brake hose (30) to cylinder housing (20).

42.6-l 1 O/3 F 2
 EXIT

8 Fasten plug connection (26) to cylinder housing

(20). Insert cable of slip sensor (25) into plug connec-
tion (26).

9 Connect brake line (4) to brake hose (71, making

sure that the brake hose is not twisted.

Attention!
Holder (5) has a double hex. locking plate (8). Insert
brake hose (7) into locking plate in such a manner
fhat hose will not wipe against any obstacles at the
left or right at full steering lock.

Brake line
Holder on frame floor
Brake hose holder
Brake hose
Locking plate
Coupling nut

10 Bleed front wheel brake circuit (42-010).

Attention!
Check brake system for leaks!

Upon bleeding, actuate brake pedal energetically

several times to obtain the correct clearance between
brake disk and brake pad. Then, with the engine run-
ning, perform leak test by actuating brake pedal at
approx. 200-300 N. The established pressure should
be maintained for some time, brake pedal should not
permit additional depression. Check all connections
for leaks. Top up brake fluid in expansion tank of
tandem main cylinder, if required.

4 2 . 6 - l 10/4 F 2
 EXIT

42-120 Removal and installation of fixed caliper on rear axle

Data

Fixed caliper make Bend ix, Teves

Fixed caliper piston dia. 35

Shaft width for brake pads 62 + 0.2

Disk contact width a approx. 12

a 1

a Disk contact width

1 Fixed caliper
2 Brake pad

Tightening torques Nm

Self-locking hex. head screw for fastening

50
fixed caliper to wheel carrier of rear axle

Brake hose to fixed caliper 15

Special tools

000 589 76 03 00
001 589 72 21 00 I

Conventional tool

e.g. Hazet, D-5630 Remscheid

Open double box wrench 9 x 11
order no. 612

Note

For loosening and tightening brake lines, use con-

ventional open double box wrench or open box
wrench element only.

42.6-120/l F 3
 EXIT

Removal

1 Pump brake fluid out of rear brake circuit

through an opened vent screw.

2 Loosen brake hose (20) on holder (34) of frame

floor and unscrew from fixed caliper. Close all
connections immediately with rubber plugs.

3 Unscrew hex. head screws (2) and remove fixed

caliper.

Installation

Attention!
When Installing a new fixed caliper, proceed as
follows:

Calipers from different manufacturers may be

installed on rear axle. However, the fixed calipers
should have the same piston dia.

When replacing a fixed caliper, make sure to install

only a fixed caliper approved for the respective
model. The fixed caliper for model 201.034 has
code number 11 (refer to arrow).

4 2 . 6 - l 20/2 F 2
 EXIT

15 16 29 12 Ii . 11 4 5
I I J I I

-8

1 Fixed caliper
2 Hex. head screw
4 Wheel carrier
5 Double-row angular ball bearing
8 Lock screw
11 Cover plate 14-
12 Brake disk
14 Fitted pin 24--
15 Rear axle shaft flange
16 Locking ring
20 Brake shoes
24 Pressure spring

4 Position fixed caliper against wheel carrier (4).

Screw-in new self-locking hex. head screws (2) and
tighten to 50 Nm by means of a torque wrench
(060).

Note: Use self-locking hex. head screws M 10 x 22

only once.

If the screw-in torque of the new self-locking hex.

head bolts is too high, clean threads in wheel carrier
by means of a tap M 10 from residual glue of micro-
encapsulated screws.

4 2 . 6 - l 2013 F 2
 EXIT

5 Tighten brake hose (20) with special tools torque

wrench 001 589 72 21 00 (060) and box wrench
element 000 589 76 03 00 to 15 Nm.

6 Connect brake hose to brake line on holder of

frame floor. Pay attention to perfect installation of
hose.

7 Bleed rear axle brake circuit (42-010). Use a

straight double-box wrench 9 mm for this purpose.

Attention!
Check brake system for leaks!

Upon bleeding, actuate brake pedal energetically

several times to obtain the correct clearance betweer
brake disk and brake pad. Then, with the engine
running, perform leak test by actuating brake pedal
at approx. 200-300 N. The established pressure
should be maintained for some time, brake pedal
should not permit additional depression. Check all
connections for leaks. Top up brake fluid in expan-
sion tank of tandem main cylinder, if required.

42.6- 120/4 F 3
 EXIT

42-l 60 Replacing brake pads

A. Fixed caliper

Data

Model 201.02, 201.12 201.03

Fixed caliper dia.

Thickness of backing pad for lining

Permissible wear of brake lining up to

2
a remaining lining thickness of

Width of brake pad max. 61.75

Effective brake surface per axle (cm2 ) 88

Thickness of brake disk 9

Wear limit 7.3

Limit dimension during maintenance ) 7.6

1 Refer to Maintenance Manual Volume 2.

Special tools

42.6-160/l F 3
 EXIT

Note

Replace brake pads when the lining is down to 2 mm

or when greasy. Use only approved lining grades in
sets.

When the brake pads are worn down to the lining

backing plate beyond the permissible lining thick-
- 2
ness, the fixed caliper may suffer damage since the
web (arrow) between the sealing ring groove and the -2Q
dust cap will fracture and the caliper will then leak. - 7

12-5518

Perform a high and a low-pressure test (42-015)

if brake pads are excessively worn out.

To prevent canting of piston, pistons may be pushed

back to their end position by means of piston resett-
ing device (031) only.

Removal

1 Knock holding pins (17) out of fixed caliper by

means of a punch (035). Remove cross spring.

42.6-160/2 F 3
 EXIT

2 Push brake pads (18) out of fixed caliper by

means of pushing lever (034).

Note: If brake pad is rusted down, use puller (032)

for removal of stuck brake pads.

If brake pad wear is high, check pistons for easy

operation. If pistons are hard to move, recondition
fixed caliper.

Brake disks which are badly contaminated at braking

surfaces by deposits from lining (indicated by gray or
blue discoloration of brake surfaces) must be cleaned
prior to installing new brake pads (42-260).

3 Clean guide surface for brake pad in fixed caliper

(2) with brake caliper brush (030).

4 Check dust cap for cracks. If dust cap is damaged,

remove and disassemble fixed caliper, since penetrat-
ing dirt will quickly lead to leaks in fixed caliper.

5 To prevent overflowing of expansion tank when the

piston is pushed back, draw some brake fluid from
expansion tank.

6 Push both pistons back with resetting device (031).

42.6-160/3 F 2
 EXIT

7 Measure thickness of brake disk. To make sure that

the wear limit is not below specifications up to next
change of brake lining, the dimension should be 0.3
mm above permissible wear limit of 7.3 mm.

8 If dimensions are below permitted test dimension

of 7.6 mm, renew brake disk (42-220).

Installation

9 Lightly coat brake pads at spots indicated by arrows

in illustration with specified lubricant (refer to table)
and insert brake pad into caliper.

10 Position cross spring (16) and knock holding pin

(17) into fixed caliper.

11 Actuate brake pedal several times energetically

until firm resistance is felt. Then check level of brake
fluid in expansion tank and top up, if required.

Note: New brake pads must be braked-in carefully,

that is, the vehicle should be braked several times from
80 to 40 km/h at slight pedal pressure.

Prior to each deceleration, permit brake to cool

slightly. Braking to a stop under deceleration should
be attempted only with run-in linings.

42.6-160/4
 EXIT

B. Floating caliper

Data

Model

Floating caliper piston dia. 54

Thickness of brake pad with backing plate

17.5 19.3
for lining

Thickness of backing plate for lining 5.5 6.2

Permissible wear of brake lining up to

3.5
a remaining lining thickness of

Width of brake pad max.

Effective brake surface per axle (

Thickness of brake disk

Limit dimension during

) Refer to Maintenance Manual Volume 2.

Tightening torque Nm

Self-locking hex. head screw for fastening

35
cylinder housing to brake carrier
- -

Special tool

000589524300

Note

Attention!
On vehicles with modified brake hose layout
(brake hose holder on spring dome), 2nd ver-
sion, start of 1985, swing cylinder housing
upward for changing brake pad.

42.6-160/5 F 3
 EXIT

Replace brake pads when the lining is down to

3.5 mm or when greasy. Install only approved
lining grades in sets.

Perform a high and a low-pressure test (40-015)

if brake pads are excessively worn out.

To prevent canting of piston, piston may be pushed

back to their end position by means of piston resett-
ing device (031) only.

Brake hose layout 1st version

Brake hose layout 2nd version

Removal

1 Lift the two holding lugs attached laterally on

cover of plug connection by means of a screw driver
and open cover. Do not use force. Remove cable of
clip sensor (25) from plug connection (26) on float-
ing caliper and do not pull on cable.

2 Unscrew upper hex. head screw while applying

counterhold to sliding bolt (23).

Brake hose layout 1st version

42.6- 160/6 F3
 EXIT

3 Swing cylinder housing (20) in downward direc-

tion and connect to torsion bar by means of a suit-
able hook. Remove both brake pads (18) from
brake carrier (21).

Brake hose layout 1st version

4 Unscrew lower hex. head screw while applying

counterhold to sliding bolt (23).

Brake hose layout 2nd version

5 Swing cylinder housing (20) upward and hang up

on wheelhouse with a suitable hook. Remove both
brake pads (18) from brake carrier (21).

Attention!
After swinging cylinder housing in upward direc-
tion, make sure that the sliding bolts are not dis-
torted. Never use cylinder housing for the purpose
of changing the steering lock.

Brake hose layout 2nd version

6 Pull clip sensor (25) out of lining backup plate.

Note: On floating caliper wear limit indicator is on

inner brake pad only.

Attention!
Renew clip sensor on which the insulating layer of
contact plate has been rubbed through or where
damage on a part of sensor including line insulation
shows up.

4 2 . 6 - l 60/7 F 2
 EXIT

Note: If high brake pad wear shows up, check piston

and slide bolt for easy operation. If piston is hard
to move, recondition floating caliper.

Brake disks which are badly contaminated at braking

surfaces by deposits from lining (indicated by gray or
blue discoloration of brake surfaces), must be cleaned
prior to installing new brake pads (42-260).

7 Clean contact surface of brake pads in brake carrier.

8 Check dust cap (9) for cracks. If dust cap is dam-

aged, remove and disassemble floating caliper, since
penetrating dirt will quickly lead to leaks in floating
caliper.

9 To prevent overflowing of expansion tank when the

piston is pushed back, draw some brake fluid from
expansion tank.

10 Push piston (2) back with resetting device (031).

11 Check air shafts of vented brake disks for con-

tamination and clean air shafts, if required.

12 Measure thickness of brake disks. To make sure

that up to next change of brake lining the wear limit
is not less than specified, pay attention to limit
dimension (refer to Data).

13 If the limit dimension is less than specified,

renew brake disk (42-220).

42.6-160/8 F 3
 EXIT

Installation

14 Insert both brake pads (18) into brake carrier

(21) making sure that the spring clamp (16) is in
parallel with upper edge of lining.

15 Insert clip sensor (25) into inner brake pad.

16 Fasten cylinder housing (20) with a new self-

locking hex. head screw to brake carrier (21),
while applying counterhold to sliding bolt (23).
Tightening torque 35 Nm. Check bellows (24) for
damage.

Note: Use self-locking hex. head screws only once.

17 Wind up cable of clip sensor (25) in spiral-shape

and insert into plug connection (26) on floating
caliper. Close cover of plug connection.

18 Operate brake pedal several times energetically

until firm resistance is felt. Then check level of brake
fluid in expansion tank and top up, if required.

Note: The new brake pads must be braked-in carefully,

that is, brake vehicle several times from 80 to 40 km/h
at low pedal pressure.

Prior to each deceleration, permit brake to cool

slightly. Braking to a stop at high deceleration should
be attempted only with run-in linings.

42.6- 16019 F 3
 EXIT

42-220 Removal and installation of brake disk on front axle

Data

Model 201.022/023/024 201.028/029 201.03

122/126 128

Thickness of brake disk 22

Limit dimension during maintenance ) 9.5 20

Wear limit 9 19.4

67.07
Fitted bore dia.
67.00

Lateral runout max. 0.12

1 Refer to Maintenance Manual Volume 2.

Tightening torque NIYI

Hex. head screw for fastening floating

115
caliper to steering knuckle

Lock screw for fastening brake disk

10
to front wheel hub

Special tools

363 589 02 21 00 126589001900

I I

Conventional tool

e.g. Mahr, D-7300 Esslingen

Dial gauge A 1 DIN 878
order no. 810

42.6-220/f F 3
 EXIT

Note

When checking brake disk, proceed as follows:

a) Measure thickness of brake disk between cover plate

and floating caliper, or with brake pads removed,
in shaft by means of slide gauge.

b) Check visually.

Vented brake disks with hairline cracks up to 25 mm

length, caused by excessive stress, need not be
renewed,

Brake disks with ruptured cracks, with score marks

deeper than 0.15 mm and at end of wear limit,
must be renewed.

20

8-
lo-

-33

33

9-

5 6 -

Layout with solid brake disk Layout with vented brake disk

3 Self-locking 10 Front wheel hub 3 Self-locking 10 Front wheel hub

hex. head screw 20 Cylinder housing hex. head screw 20 Cylinder housing
5 Cover plate 21 Brake carrier 5 Cover plate 21 Brake carrier
6 Brake drsk 33 Steering knuckle 6 Brake disk 25 Clip sensor
8 Lock screw 8 Lock screw 26 Plug connection
9 Clamprng sleeve 9 Clamping sleeve 33 Steering knuckle

42.6-22012 F 3
 EXIT

Removal

1 Unscrew hex. head screws (3) and remove floating

caliper from steering knuckle (33).

2 Hang up floating caliper including brake hose in

wheelhouse by means of a suitable hook.

Note: The hook is self-made. Brake hose should not

undergo tensile stress.

3 On vented brake disk and starting September

1984 on solid brake disk, unscrew lock screw (8)
first, then remove brake disk (6) from wheel hub
(10).

Installation

Note: Prior to installation of brake disk, remove rust,

if any, on flange of brake disk and front wheel hub.
Make sure that there is no burr at fitting point of
brake disk. Check attachment of cover plate.

Replacement brake disks are protected against corro-

sion by means of nitro cellulose paint. Prior to installa-
tion, these brake disks must be cleaned with a solvent.
Make sure that safety rules are observed.

4 Place brake disk on front wheel hub (10). Make

sure that the two dowel sleeves (9) are perfectly
seated in brake disk cup. Mount lock screw (8) and
tighten to 10 Nm.

42.6-22013 F 2
 EXIT

5 Fasten floating caliper with new self-locking hex.

screws (3) to steering knuckle (33). Pay attention
to perfect installation of brake hose (42-100).

Tighten hex. head screws to 115 Nm.

Note: Use self-locking hex. head screws only once.

If the tightening torque of the new self-locking hex.

head screws is very high, clean threads in floating
caliper with a tap M 12 x 1.5 from residual glue of
micro-encapsulated screws.

Prior to moving off, actuate brake pedal several

times energetically to obtain the correct clearance
between brake disk and brake pad. Then top up
brake fluid supply in expansion tank of tandem
main cylinder.

Note: If during the test drive (mainly after driving

around a bend) a different pedal travel shows up,
check wheel bearing end play of front wheel hubs
and adjust, if applicable (33-300).
If required, measure lateral runout of brake disk at
outer dia.

If lateral runout of brake disk is too high, displace

brake disk on front wheel hub. Renew brake disk,
if required.

42.6-22014 F 2
..................... ........................................ .... ........................................... EXIT

42-228 Removal and installation of brake disk on rear axle

Data

Thickness of brake disk 9

Limit dimension during maintenance ) 7.6

Wear limit 7.3

Disk dia. 258 + 0.2

67.07
Fitted bore dia.
67 .OO
-
ID for parking brake 164 + 0.2

Lateral runout max. 0.15

1 Refer to Maintenance Manual Volume 2.

Lubricants

Molykote-Paste U Molykote-Paste G Rapid Liqui-Moly-Paste 36

Tightening torque Nm

Hex. head screw for attaching fixed caliper

50
to wheel carrier of rear axle

Lock screw for fastening brake disk

10
to rear axle shaft flange

Special tools

363 589 02 21 00 126589001900

\ /

Conventional tool

e.g. Mahr, D-7300 Esslingen

Dial gauge A 1 DIN 878
order no. 810

42.6-22811 F 3
 EXIT
Note

When checking brake disk, proceed as follows:

a) Measure thickness of brake disk between cover

plate and caliper or with brake pads removed, in
lining shaft with slide gauge.

b) Check visually.

If cracks are larger (not measurable), with score marks

deeper than 0.5 mm and when attaining wear limit,
renew brake disks.

Removal

8 -

1 Fixed caliper
2 Self-locking hex. head screw
4 Wheel carrier
5 Two-row angular ball bearing
8 Lock screw
11 Cover plate
12 Brake disk
14 Fitted pin 14-
15 Rear axle shaft flange
16 Locking ring 24-
20 Brake shoes
24 Pressure spring

1 Unscrew hex. head screws (2) and remove fixed

caliper from wheel carrier (4).

42.6-22812 F 3
 EXIT

2 Hang up fixed caliper including brake hose with a

sui table hook on spring.

Note: The hook is self-made. Do not expose brake

hose to tensile stress.

3 With lock screw (8) installed, unscrew this

screw first, then remove brake disk (12) from
rear axle shaft flange (15).

Loosen stuck brake disks by light blows with a plastic

hammer from seat of rear axle shaft flange. Make sure
that the parking brake is completely released.

Installation

4 Coat fitted seat of rear axle shaft flange with a

heat-resistant long-term lubricant (Molykote-Paste
U, Molykote-Paste G Rapid, Liqui-Moly-Paste 36),
so that the brake disk can be easily removed from rear
axle shaft flange later on.

Note: Spare brake disks are protected against corrosion

by means of nitro-cellulose paint. For this reason, these
brake disks should be cleaned with a solvent prior to
installation. Make sure that safety rules are observed.

5 Place brake disk (12) on rear axle shaft flange.

Make sure that the dowel pin (14) is correctly
entering brake disk. Screw in lock screw (8) and
tighten to 10 Nm.

6 Attach caliper with new self-locking hex. head

screws to wheel carrier. Tighten hex. head screws
to 50 Nm (42-120).

Note: Use self-locking hex. head screws M 10 x 22

only once.

If the screw-in torque of the new self-locking hex.

head screws is very high, clean threads in wheel
carrier with a tap M 10 from residual glue of micro-
encapsulated screws.

42.6-228/3 F 2
 EXIT

Attention!
Prior to moving off, actuate brake pedal several times
energetically, to obtain the correct clearance between
brake disk and brake pad. Then top up brake fluid
supply in expansion tank of tandem main cylinder.

Note: If during a trial run (mainly after driving

around bends) a different pedal travel is observed,
measure lateral runout of brake disk at OD.
Simultaneously, check rear axle shaft flanges for
vertical and lateral runout (35-130).

If lateral runout of brake disk is too high, renew

brake disk.

42.6-22814
 EXIT

$2-260 Cleaning brake disks

1 Brake disks of front axle . . . . . .. . , . . , . . . . . * Cleaning pads 2 0 1 5 8 9 0 0 2 8 0 0 (95 m m wide)

Cleaning pads 1 2 4 5 8 9 0 0 2 8 0 0 (110 mm wide)
2 Brake disks of rear axle. . . . . , , . . . . . * . . , , . . Cleaning pads 2 0 1 5 8 9 0 1 2 8 0 0

Special tools

201 589 00 28 00 124589002800 201 589 01 28 00

Note

When cleaning brake disks while driving, always provide only one axle with cleaning pads. Do not actuate brake
in jerks, to make sure that the emery cloth cannot be pulled from cleaning pads.

Owing to their low speed and the resulting inadequate cleaning effect, drum-type and brake dynamometers are
unsuitable for cleaning purposes.

42.6-260/l F 3
 EXIT

Front axle

1 Remove brake pads (42-160).

2 Install cleaning pads 201 589 00 28 00 or

124 589 00 28 00 (050) on front axle only.

3 Clean brake disks,

a) Drive respective wheel with a suitable drive unit

(e.g. finish balancer made by Hofmann) and press
cleaning pads several times against brake disk under
slight foot pressure against brake pedal.

b) Drive vehicle at a speed of approx. 30 km/h for a

distance of 300 m while pressing cleaning pads
several times quickly against brake disks under a
slight foot pressure of approx. 50 N.

4 Remove cleaning pads.

5 Install brake pedals (42-160).

Rear axle

6 Remove brake pads (42-160).

7 Install cleaning pads 2 0 1 5 8 9 0 1 2 8 0 0 ( 0 5 0 ) at

rear axle only.

Drive vehicle at a speed of approx. 30 km/h for a

distance of 300 m while stepping against brake
pedal at a low pedal pressure of approx. 50 N to
force the cleaning pads for a short moment against
the brake disks.

Attention!
With the vehicle jacked up, the rear wheels should
never be driven by the engine or by means of an-
other drive unit.

8 Remove cleaning pads.

9 Install brake pads (42-160).

42.6-26012 F 3
 EXIT

42-310 Removal and installation of stepped tandem main cylinder

Data

Model 20 1.023/024/028 20 1.029/034/ 128

122/126

Pushrod circuit

Cylinder dia.

Floating circuit

Tightening torques Nm

Hex. nuts for fastening main cylinder to 15

brake unit

Coupling nut of brake line on main cylinder 10

Special tools

I I c
001 589 72 21 00 000 589 75 03 00
I I

Conventional tool

e.g. Hazet, D-5630 Remscheid

Open double-box wrench 9 x 11 mm
order no. 6 12

Note

During removal and installation of tandem main

cylinder note the following:

Push brake line (11) slightly sideways. Remove and

install tandem main cylinder in axial direction to
push rod in brake carrier. Do not tilt tandem main
cylinder, since-otherwise the push rod will be forced
out of its axial position and may brake out of hold-
ing lugs on control member.

42.6-310/l F 3
 EXIT

For loosening and tightening brake lines use conven-

tional open double-box wrench or open box wrench
element only.

Removal

1 Pump out brake fluid via an open bleeder plug of

front axle and rear axle brake circuit. Make sure that
all chambers of expansion tank are drained.

2 Loosen plug connection (3) on contact element of

warning device, lifting holding lugs with a small screw
driver for this purpose. On vehicles with manual
transmission, remove connecting hose on connection
(7) to master cylinder.

3 Remove expansion tank from tandem main cylinder.

4 Disconnect brake lines to front and rear wheel

brake on tandem main cylinder.

Immediately close all brake lines with rubber caps

and connections on tandem main cylinder with blind
plugs.

5 Loosen tandem main cylinder on brake unit and

remove, paying attention to sealing ring located in
groove in flange of tandem main cylinder.

Attention!
In the event of a loss of brake fluid, which cannot be
observed visually, check whether brake fluid has
entered the brake booster through a leaking secon-
dary seal in tandem main cylinder. If so, proceed as
follows:

Do not remove brake booster.

Draw off brake fluid.

Change brake booster if there are more than

100 cc of brake fluid in unit.

42.6-310/2 F 3
 EXIT

Note: The flexible diaphragm is resistant to brake

fluid, while the reaction disk and the plate valve in
control member are not. For this reason, draw off
brake fluid only with the brake booster installed.
With the brake booster installed, no brake fluid can
reach the reaction disk or the plate valve up to
100 cc.

Installation

Attention!
Always renew sealing ring between tandem main
cylinder and brake booster, since the connection
must be absolutely sealtight.

6 Insert sealing ring (11) into groove of tandem

main cylinder (12) and fasten main cylinder to
brake unit (10). Tighten hex. nuts to 15 Nm.
1424 -10948

7 Connect brake lines on tandem main cylinder.

For this purpose, use torque wrench 001 589 72 21 00
with open box end element 000 589 75 03 00.

Tightening torque 10 Nm.

8 Install expansion tank and fill with brake fluid.

Make sure that all chambers are completely filled
with brake fluid.

9 Connect plug connection on contact element of

warning device.

10 Bleed brakes and check for leaks (42-010 and

42-015).

42.6-31013 F 3
 EXIT

42-315 Disassembly, checkup and assembly of stepped tandem main cylinder

Girling tandem main cylinder

1 Tank plug
2 O-ring. , , , , . . . . , . , , . . . . . . . . . , . . , , . . Renew
3 Piston (push rod circuit) . . . . . . . . . . . . . . . . Renew
4 Stop washer
5 Locking ring . . . . . . , . . . . . . , . . . . . . . , . . Pay attention to correct seat
7 Bushing . . . . . . . , . . . . . . . . , . . . . , . . . . . Renew
8 Stop washer
10 Primary sleeve . . . . . . . . . . . . . . . . . . . . . . , Renew
11 Supporting ring
17 Compression spring . . . . . . . , . . . . . . . . . . . . Renew
18 Separating sleeve .......,............. Renew
20 Piston (floating circuit) . . . . . . . , . . . , . . . . . Renew
21 Compression spring .........,.......... Renew
22 Housing . . . . . . . . . , . . . . . . . . . . . . . . . . . Pay attention to score marks
26 Expansion tank ..,........ ........... Clean
27 Cyl. pin
31 Cover
32 Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . Clean

42.6-315/l F 2
 EXIT

Bendix tandem main cylinder

1 Tank plug
3 Piston (push rod circuit) ................ Renew
4 Stop washer
5 Locking ring........................ Pay attention to correct seat
6 .....................
Secondary sleeve Renew
7 Bushing ........................... Renew
10 Primary sleeve ....................... Renew
11 Supporting ring
17 Compression spring .................... Renew
18 Separating sleeve ..................... Renew
20 Piston (floating circuit) ................. Renew
21 Compression spring .................... Renew
22 Housing ........................... Pay attention to score marks
26 Expansion tank ...................... Clean
27 Cyl. pin
31 Cover
32 Strainer ........................... Clean

42.6-31512 F 2
 EXIT

Teves tandem main cylinder

1 Tank plug
2 O-ring. . . . . . . . . . . , . . . . . . . . . . . . . . . . . Renew
3 Piston (push rod circuit) . . . . . . . . . . . . . , . . Renew
4 Stop washer
5 Locking ring . . . . . . . . . . . . . . . . . . . . . . . . Pay attention to correct seat
7 Bushing . . . . . . . , . . . . . . . . . . . . . . . . . . . Renew
8 Stop washer
10 Primary sleeve . . . . . . . . . . . . . . . . . . . . . . . Renew
11 Supporting ring
17 Compression spring ..,,................ Renew
18 Separating sleeve .............,....,. . Renew
20 Piston (floating circuit) . . . . . . . . . . . . . . , , . Renew
21 Compression spring ....,........,...,.. Renew
22 Housing . . . . . . , . , . . . . . . . , . . . , . . . . . . Pay attention to score marks
26 Expansion tank . . . . . . . . . . . . . . . . . . , . . . Clean
27 Cyl. pin
31 Cover
32 Strainer . . . . . . . . . . . . . . , . . . . . . . . . . . . Clean

42.6-31613 F 2
 EXIT

Data Tandem main cylinder

Housing Dia. when new

Permissible out-of-round

Dia. when new

Clearance 0.02-O. 15

Stroke 17 15 16.8 16.2

Note

Repair sets and housings from different manu-

facturers can be optionally used.

Disassembly

1 Pull expansion tank and then tank plug out of

tandem main cylinder.

2 Slightly push in piston (3) by means of a man-

drel and pull cyl. pin (27) out of housing with
suitable pliers.

42.6-31514 F 3
 EXIT

3 Take locking ring (5) out of housing, then

remove piston (3) together with secondary sealing
pack out of housing.

4 Knock out complete piston for floating circuit

by means of light blows against housing.

5 Unscrew closing cover (4) and remove strainer.

Note: The contact element (30) cannot be

removed.

142-23958

Checkup

6 Clean all parts thoroughly with new brake fluid,

making sure that all residue is flushed out of
housing and expansion tank.

7 Check bore in housing for score marks and

damage.

Do not refinish scored or damaged housings.

Assembly

8 Slightly rub bore of housing with brake cylinder

paste.

9 Separate packing sleeves. Remove sealing pack

and piston for push rod circuit from sleeve (041).

42.6-31515 F 3
 EXIT

10 Clamp housing slightly tilted with bore in down-

ward direction. Slip sleeve (040) together with
floating piston by means of a screwdriver up to
stop into housing. Make sure that the guide slot in
piston (refer to arrow) is vertical. Position of piston
can be corrected as required with screwdriver.

11 Hold piston in place with mandrel. Slip cyl. pin

(27) with chamfer first into bore up to stop. The
cyl. pin should project no more than 2-3 mm.
Remove mandrel and sleeve.

12 Clamp tandem main cylinder in such a manner

that the cylinder bore is pointing upward.

13 Introduce secondary seal pack together with

push rod piston into cylinder housing and push
downward by means of mandrel.

142-27180

14 Hold piston in place and mount locking ring (5).

Make sure that the ring is correctly seated in groove
of housing.

42.6-31516 F 2
 EXIT

Mounting expansion tank

15 Clamp tandem main cylinder in horizontal

position. Insert straliner into tank and screw on
closing cover.

16 Rub tank plug (1) lightly with brake cylinder

paste and push into housing.

17 Insert expansion tank (26) first with one pipe

connection into housing, rotate by180 and then
push second pipe connection into housing. Make
sure of perfect seat.

42.6-31517 F 2
 EXIT

42-510 Removal and installation of parking brake lever

Removal

1 Disconnect return spring (12) on cable1 control

compensation.

2 Pull-off handle (10) and remove lining (7) fron1

lever.

3 Remove center console.

4 Remove switch for warning lamp (2).

5 Loosen hex. screws (5) and remove lever ( 1).

42.6-510/l
 EXIT

6 Remove flange bolt (8) and take off brake cable

(17).

? 7 79

1 Lever 8 Flange bolt

2 Switch 9 Push button
3 Spring 10 Handle
4 Paw1 rod 14 Locking paw1
5 Hex. head screw 16 Rubber grommet
6 Detent curve 17 Front brake cable
7 Lining

42.6-51 O/2
 EXIT

Installation
_

7 Attach brake cable (17) with flange bolt (8) to

lever (1). Cotter flange bolt.

8 Fasten lever (1) with both hex. head screws (5)

to propeller shaft tunnel.

9 Install switch for warning lamp (2).

10 Install center console.

11 Install lining (7) and handle (10).

12 Attach return spring (12) to cable control

compensation.

13 Adjust parking brake (42-540).

42.6-510/3
 EXIT

42-520 Removal and installation of front brake cable control

_ _.

Removal

1 Disconnect return spring (12) on cable control

compensation.

2 Unscrew hex. head screw by means of which the

brake cable (17) is fastened to intermediate lever (6)
and remove brake cable.

3 Remove lever of parking brake (42-510).

4 Loosen brake cable (17) on lever (1) and pull out

toward the rear through frame floor.

Installation

5 Guide brake cable (17) through frame floor and

insert rubber grommet into frame floor.

For further installation proceed vice versa.

6 Adjust parking brake (42-540).

42.6-520/l
 EXIT

42-525 Removal and installation of rear brake cable control

Special tools

001 589 72 21 00

Removal

1 Remove brake shoes of parking brake (42-530).

2 Unscrew hex. head screw (25) from wheel carrier

(4) and remove brake cable control (10).

3 Disconnect return spring ( 12) from holder ( 14).

4 Screw back adjusting screw (3) of adjusting

bracket ( 1).

5 Remove front brake cable (17) from intermediate

lever (6).

6 Disconnect intermediate lever (6) on bearing of

frame floor (2).

7 Disconnect brake control (10) from compensating

lever (7).

8 Remove spring clamp ( 131, remove cable control

(10) from holder (14).

42.6-52511 F 3
 EXIT

Adjusting bracket 10 Rear brake cable control

Bearing on frame floor Draw spring
Adjusting screw ;: Spring clamp
Guide for iirtermedtate lever 14 Holder for rear brake
lntermedlate lever cable control
Compensating lever 16 Rubber grommet
Spring ctip 17 Front brake cable control

Installation

Note: During reinstallation, make sure that the rubber

grommets ( 16) are not damaged, so that no dirt can
enter cable guide.

9 Pay attention to perfect installation of brake cable

control in rubber grommet of holder on rear axle
carrier.

10 Fasten brake cable control to wheel carrier (4).

11 Attach brake cable control to compensating

lever (7). Secure brake cable control to holder (14)
by means of spring clamp (13).

12 Connect intermediate lever (6) and install front

brake cable ( 17). Attach return spring (12).

13 Install brake shoes (42-530).

14 Adjust parking brake (42-540).

42.6-525/2 F 2
 EXIT

42-530 Removal and installation of brake shoes of parking brake

Data

Brake shoe dia. 164-0.2

ID of brake disk 164 + 0.2

_----- - -~_-----~~
Brake shoe width 20

Lubricants

Molykote-Paste U Molykote-Paste G Rapid Liqui-Moly-Paste 36

~___________~_____-----~~~~-

Special tools

116589016200 112589096100 001 589 72 21 00

I I

42.6--530/l F 3
 EXIT

24 2 0 2 9 21 22 2,3 1
I I ~ ~ I

14.
24-

24

Fixed caliper 11 Cover plate 22 Adjusting wheel

2 Hex. head screw 12 Brake disk Pressure sleeve
4 Wheel carrier 13 Brake carrier z: Pressure spring
5 Two-row angular 14 Fitted pin Hex. head screw
ball bearing 15 Rear axle shaft z: Bolt
8 Locking screw flange 27 Expanding lock
10 Brake cable control 16 Locking ring 28 Supporting bolt
20 Brake shoes 29 Upper return spring
21 Thrust piece 31 Lower return spring

Removal

1 Remove brake disk (42-228).

2 Turn rear axle shaft flange (15) in such a manner

that one hole faces spring (24). Then compress
spring slightly with installer 112 589 09 61 00 (040),
turn tool by approx. 90, disconnect spring from
cover ring (19) and remove,

3 Also remove spring on other brake shoe.

42.6-53012 F 3
 EXIT

4 Disconnect return spring (31) with remover and

installer 116 589 01 62 00 (041) f r o m brake shoes
(20).

5 Pull both brake shoes (20) apart until they can

be removed over rear axle flange ( 15).

6 Disconnect return spring (29) from brake shoes

(20) and remove adjusting device (21 to 23).

7 Push bolt (26) out of expanding lock (27) and

remove expanding lock from brake cable control (10).
2 8 -

20- - 4

3 Wheel carrier 26 Bolt z- 28

10 Brake cable control 27 Expanding lock
20 Brake shoes 28 Hex. socket screw 2 6 - 20
25 Hex. head screw

42.6-553013 I= 3
 EXIT

Installation

8 Coat all bearing and sliding surfaces on expanding

lock with specified lubricant (refer to table), fasten
brake cable control (10) to expanding lock (27) with
bolt (26). Then push expanding lock toward cover
ring (19).

9 Coat threads of thrust piece (21) and cylindrical

portion of adjusting wheel (22) with specified
lubricant (refer to table). Assemble adjusting device
and turn completely back.

20 Brake shoes
21 Thrust piece
22 Adjusting wheel
23 Pressure sleeve 20 21 22 23

10 insert adjusting device (21 to 23) into both brake

shoes in such a manner that the adjusting wheel (22)
is pointing forward.

11 Connect return spring (29) to both brake shoes.

12 Pull brake shoes (20) apart, insert over rear axle

shaft flange (15) and connect to expanding lock.

13 Insert spring (24) laterally into brake shoe (20).

Introduce installer 112 589 09 61 00 (040) through
a hole of rear axle shaft flange (15), then compress
spring slightly, turn by 90 and connect to cover
ring (19). Make sure that the spring is correctly
connected.

42.6-530/4 F 3
 EXIT

14 Connect spring (31) with small eye to brake

shoes.

Note: The eyes of the return spring are of different

size. For large eye refer to arrow.

15 Connect remover and installer 116 589 01 62 00

(041) to large eye of return spring (31), then con-
nect return spring to other brake shoes (20).

16 Install brake disk (42-228).

17 Adjust parking brake (42-540).

42.6-53015 F 3
 EXIT

42-548 Readjusting or adjusting brake shoes of parking brake

Data

( Up to April 1984 As of April 1984 As of February 1987

Total ratio of parking brake

1:25.2
up to expanding lock outlet

Number of detents on detent sector 8 12

Number of detents required for locking

parking brake at medium energy of 2-3
approx. 170 N

Number of detents until effect of

1
parking brake begins

Number of teeth on adjusting wheel 8 15

Note

Readjust parking brake if the lever can be tightened

by more than 2 detents (of a total of 8 or 121,
without obtaining a braking effect.

1 Completely loosen adjusting screw (3) Make sure

that expanding locks are not preloaded.

2 At rear axle left and right unscrew one spherical

collar screw each.

3 Jack up vehicle and first turn one wheel in such a

manner that the screw hole out of which the spherical
collar screw has been screwed, points approx. 45 in
rearward upper direction.

42.6-540/l F 3
 EXIT

4 Insert screwdriver (size 4.5 mm) through hole of

disk wheel, brake disk (12) and rear axle shaft flange
(15) into adjusting wheel of readjusting device (22)
and turn adjusting wheel by means of pertinent
movements until wheel can no longer be turned.
Then turn back adjusting wheel with 8 teeth for
approx. 2-3 teeth, adjusting wheel with 15 teeth
for approx. 5-6 teeth, i.e. enough until the wheel
can be turned absolutely unrestricted.

Attention!
Adjusting position of screwdriver for adjusting
brake shoes:

Lefthand side: from below in upward direction.

Righthand side: from top in downward direction.

5 Screw in adjusting screw (3) until the brake

cables are no longer sagging.

6 Actuate parking brake several times energetically

at approx. 400 N.

7 Rotate adjusting screw (3) in adjusting bracket

(1) until the lever can be tightened for one tooth at
an energy of approx. 90-l 20 N.

i42-23217

42.6-54012 F 2