Brake Replacement Tips
1. Starting point:
It is important any defective or worn parts to be replaced. Visually check the brake disc, pads and all relevant components in the axle and the hydraulic system for any sign.
2. Rust removing:
Remove rust from the contact surface and the hub edge after dismantling the old brake discs. Use suitable tools (e.g., paper sand, wire brush, etc.).
Make sure not to damage the wheel hub. Make sure the caliper which is still connected to the hydraulic system, to be fastened and no tensile load is exerted on the brake hose.
3. Hub and contact surface cleaning:
Clean the bright metal contact surface using a brake cleaner.
4. Rust removing from the guide shafts of the caliper bracket
Remove rust and residues from the guide shafts of the dismantled caliper bracket. Use a wire brush or brake caliper file.
Check visually to make sure for no damage on caliper bracket.
5. Using grease for guide surfaces
Grease the cleaned guide surfaces of the caliper bracket with a heat-resistant, nonconductive, and solids-free (non-metallic).
Do not use copper paste
6. Brake disc fitting
Fit the new brake disc on the wheel hub and fasten with the retaining screws. Measuring the newly fitted brake discs for lateral run-out approx. 15 mm below the maximum radius using a dial gauge recommended.
7. Brake piston moving back
To prevent the piston jamming or twisting, the brake piston must always be moved back using suitable adjusting tools.
Make sure to use an appropriate tool for different versions of the caliper and/or the brake system. Manufacturer-specific requirements and special tools should be observed.
8. Contact points greasing
Metal free anti-squeal lubricant is not required where damping lacquer coatings or damping shims are fitted.
Lubrication is only vital in the contact points of the pad and on the guide shafts so use the metal free anti-squeal lubricant in the area of contact of the pad on the guide shafts.
The torque settings and guidelines of the vehicle and system manufacturers are to be observed in all steps of the repair process.
Brake
Replacement Tips
Code: WI-20, Rev.:0, Date: 15 Dec. 2016
Fault Diagnosing Checklist
Primary Checking
Check point
Description
Result
OK N.OK
Remarks / Action required
Operation before starting replacement
Before starting replacement
On roller test bench
- Front
On roller test bench
- Rear
Before starting replacement
No damage
Test Drive
Check shock
absorber
Test brake
operation
Test brake fluid
Visually check
rims / tires
Secondary Checking
Check point
Description
Result
OK N.OK
Remarks / Action required
clean (metallic bright)
Check for any damage
lateral run-out using
a dial gauge
visible damage
corrosion protection (excluding solids contents)
tightness and security
Wheel bearing
Wheel hub
Axle nut
Traverse link
mount
Supporting ball
joint Tie rod end
Wheel bolt thread
No damage
can the bolts easily be screwed in by hand?
replace in case of porosity and increased play
joint play
check sealing collars for porosity and leakage
fastening of joints (securing screws)
seal
3 play, smooth running
Brake caliper
fluid leaks, porous
fluid leaks,
smooth-running
No damage
Piston
Dust collar
Sliding
element
Caliper
housing
Brake hose
fluid leaks, porous, chafe marks
inner diameter (swollen)
screwed connection
check maximum service life
Strut
fluid leaks (detectable oil seepage)
shock-absorber efficiency test, in advance
strut fracture
shock-absorber mount
fastening
Drive shaft boot
fluid leaks, porous
Final Checking
Check point
Description
Result
OK N.OK
Remarks / Action required
Accessory and fasteners
Fitting and make sure about the centered brake disc, lateral runout
On roller test bench
After replacement
Check accessory/
set of fasteners replaced
Functional test
Test drive
Final check the
newly replaced
Fault Diagnosing
Checklist