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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.

Replacement Tips

Code: WI-20, Rev.:0, Date: 15 Dec. 2016

Fault Diagnosing Checklist

Primary Checking

Check point



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

Test brake

Test brake fluid

Visually check
rims / tires

Secondary Checking

Check point



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

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)


3 play, smooth running

Brake caliper

fluid leaks, porous

fluid leaks,

No damage


Dust collar



Brake hose

fluid leaks, porous, chafe marks

inner diameter (swollen)

screwed connection

check maximum service life


fluid leaks (detectable oil seepage)

shock-absorber efficiency test, in advance

strut fracture

shock-absorber mount


Drive shaft boot

fluid leaks, porous

Final Checking

Check point



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

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