Procedure to replace the front and rear brake pads.

Description

To prevent the problem of abnormal brake pad wear, the procedure described on the following pages must be
followed very carefully.

Involved Vehicles

29L10 - 29L12 - 29L14 - 35S10 - 35S12 - 35S14 - 35S18 - 35C10 - 35C12 - 35C14 - 35C15 - 35C18 - 40C10 - 40C12
- 40C15 - 40C18 - 45C15 - 45C18 - 50C15 - 50C18 - 60C15 - 60C18 - 65C15 - 65C18

Procedure

Replacement of the front and rear brake pads.

1) - Disconnect:
the wear sensor
the parking brake cable (Fig. A)
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Fig. A
1 - Seeger circlip

2) - Remove the outer dust cap protecting the guide bush (Fig. B).
3) - Remove the bolt (Fig. C) securing the guide bush to the brake calliper body. This procedure is required in
order to rotate the brake calliper carrier clear of the calliper body (Fig. F / G).

Fig. B Fig. C

4) - Using a suitable levering tool, carefully push back the guide bush into the brake calliper body (Fig. D). If
necessary, gently tap the carrier with a soft faced hammer (Fig. E) to release the calliper carrier from the
calliper body.

Do not use any oil, mineral grease, petroleum or

paraffin (hydrocarbons), solvents or products which
could attack the rubbers in the brake callipers.
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Fig. D Fig. E

5) - Rotate the brake calliper carrier up or down around the other guide bush (Fig. F / G).

Do not remove the guide bush.

Do not smear the bushes or their seats with grease
that is not specially designed for this purpose.

Fig. F Fig. G
Brake calliper, front brake Brake calliper, rear brake

6) - Remove the two worn brake pads from the brake calliper body.
7) - Retract the brake pistons back into their seats using the special tools designed for this job to ensure that
the pistons are retracted square into their bores and to avoid damage to the piston surfaces and gaiters.
Retracting the pistons will raise the level of the brake fluid in the reservoir, check that the fluid does not spill
out and damage the vehicle paint work.

Do not damage the dust gaiter seals because that could

lead to:
Premature brake pad wear.
Irregular wear between the brake pad on the piston
side and the brake pad on the reaction side.

8) - Allow any air trapped under the brake piston dust gaiter to escape (Fig. H).
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Do not damage the dust seals. If damaged, replace:

only the dust seals of the front and rear brake
callipers on models 40C ÷ 65C, by using the seals from
the kit from the Parts Department.
the complete rear brake calliper on models 29L ÷
35C.

Fig. H

9) - On brake calliper versions with springs on the sides as shown in Fig. L, the springs must be replaced by
springs from the kit with the seats previously cleaned. If the brake callipers however have a central spring, as
shown in Fig. M, this spring must not be replaced and also must not removed from its seat.

Ensure that the springs are fitted correctly to prevent

deformation.

Fig. L Fig. M

10) - Clean the brake pad contact surfaces of the calliper body using suitable materials and products then fit
the new brake pads.

If there are arrows on the brake pads, as shown in Fig.

N, these must point towards the rotation of the brake
disc.
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Fig. N

Secure the brake pad wear sensor to the brake pad

with the furthest protruding side of the sensor
("sonde") pointing towards the side of the brake pad
friction face (Fig. P).
The brake pad with wear sensor must be fitted in the
position described in the Workshop Manual.

Fig. P Fig. Q
Correct connection Improper connection

11) - Insert the wear sensor connector through the spring hole or through the hole in the brake calliper body
and allow it to project through the outside of the brake calliper.
12) - Carefully clean the seat and the end of the guide bush using suitable materials and products.
13) - Rotate the brake calliper carrier back into position around the fitted guide bush and secure the other
bush in its seat in the brake calliper body without damaging the dust seals.
14) - Replace the bolts removed earlier and tighten the new bolts to a torque setting of 28 ÷32 Nm (fig. R).
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Fig. R

15) - Refit the dust caps removed earlier and pay attention to the following:
Carefully clean the dust cap seats in the brake calliper.
Rotate the dust caps around in the brake calliper to ensure that they engage correctly in their
seats.
If the dust caps removed earlier are damaged, these must be replaced with dust caps from the relevant
kit.

16) - Reconnect the wear sensor.

17) - Refit the parking brake cable on the mounting bracket and secure with the Seeger circlip (Fig. A).
18) - Run the pads in avoiding braking at high speeds for the first 100 km.

To be avoided:
The brake calliper must not be exposed to shocks.
Avoid contact of the rubber dust caps, dust gaiter seals and dust covers with sharp metal tools.
Damaged components mean correct sealing can no longer be guaranteed causing the ingress of
water and contaminates. This leads to oxidation, resulting in binding of moving parts.
Do not use unsuitable oils and greases which attack the sealing properties allowing the ingress
of water and contaminates with resulting binding of moving parts (use, if necessary,
"SYNTHESO GLK 1PF" grease from "KLÜBER").
Do not soil the brake pads with fluids or grease. A differing friction coefficient between the two
brake pads can cause irregular wear.