Front Brake Caliper, Servicing

Overview - Brake Caliper FN 3

• Install the entire repair kit when servicing.
• Only use mineral spirits to clean the brakes.
• Apply a thin coat of Assembly Paste -G 052 150 A2- to brake cylinders, pistons and seals.

1. 1
   Dust Cap

   • Attach to bleeder valve
2. 2
   Bleeder Valve

   • 10 N·m
   • Apply a thin coat of aAssembly Paste -G 052 150 A2- to the threads before screwing in.
3. 3
   Caps

   • Insert in bushing
4. 4
   Guide Pins

   • 30 N·m
5. 5
   Bearing Bushing

   • Insert in brake caliper
6. 6
   Brake Caliper
7. 7
   Brake Carrier

   • Bolt to brake caliper
8. 8
   Spring

   • Insert with both ends in holes of brake caliper
9. 9
   Seal

   • Removing and installing.
10. 10
    Piston

    • Removing and installing.
    • Apply a thin coat of Assembly Paste -G 052 150 A2- to piston beforehand
11. 11
    Protective Cap

    • Removing and installing.
    • Do not damage when inserting the piston

FN 3 Brake Caliper Piston, Removing and Installing

Special tools and workshop equipment required

• Trim Removal Wedge -3409-
• Piston Resetting Tool -T10145-
• Piston Resetting Tool - Cap /6 -T10146/6-

Removing

• Use compressed air to push the piston out of the brake caliper.

Place A Wooden Board Into the Recess So the Piston Is Not Damaged.

• Remove the protective cap from the brake caliper using the Trim Removal Wedge -3409-.

• Remove the seal with the Trim Removal Wedge -3409-

When removing, make sure that the cylinder surface is not damaged.

Installing

• The surface of the piston and seal must only be cleaned with mineral spirits and then dried.
• Thinly coat piston and seal with Assembly Paste -G 052 150 A2- before inserting.
• Insert the seal in brake caliper.

• Insert the protective cap -A- into the Piston Resetting Tool - Cap /6 -T10146/6--1-.

• Press the protective cap with the assembly tool -1- and the piston resetting tool -2- into the brake caliper so that it contacts the brake caliper all around.

Check the Seating of Protective Caps

• Protective cap must no longer be able to be pulled from brake caliper by hand.

• Press the piston lightly against the protective cap and lock it into position, for example with the trim removal wedge -2-.

Do not tilt the piston in order to avoid damaging the sealing boot.

• Blow the protective cap on with pressurized air (maximum 3 bar (43 psi)) -1-. This will force the protective cap onto the piston.

• Press the piston into brake caliper using a piston resetting tool -1-.

Outer sealing lip of protective cap will then engage in the piston groove.