HP-2 Dual Piston Calipers - Steel
Note:
^ Always install complete repair kit
^ After replacing brake pads and before moving vehicle, depress brake pedal several times firmly to properly seat brake pads in their normal operating position.
^ When siphoning brake fluid, always use a bleeder bottle that is used exclusively for brake fluid. Brake fluid is poisonous. NEVER siphon brake fluid with your mouth!
^ Brake line tightening torque: 15 Nm.
1. Hex bolt, 25 Nm
2. Bracket
^ Bolt to brake caliper housing
^ Insert harness connector for brake pad wear indicator
3. Retaining spring
4. Ribbed bolt w/washer assembly, 200 Nm
^ Clean ribs if reusing
5. Brake line, 15 Nm
6. Brake caliper with vibration dampener
^ If repair work is necessary, do not hang by brake hose. Secure on structure using wire
^ No repair work is permitted at the brake caliper except for "replacing brake pads" and "servicing front brake caliper".
7. Torx bolts, 25 Nm
^ Always replace
^ Remove and install using commercially available Torx insert (e.g. Hazet T40)
^ Included in repair kit for brake pads
8. Harness connector
^ Remove from bracket at brake caliper when changing brake pads
9. Brake hose
^ Do not unscrew brake pads when removing
10. Wire bracket
^ Insert line for brake pad wear indicator in line retainer
11. Brake pads
^ With vibration dampener and antirattle spring
^ Pads on both sides of axle must always be replaced together.
^ Different on left and right side
^ Removing and installing; Refer to brake pads
^ With wear indicator
- Warning lamp lights when relevant wear limit (3 mm) has been reached
^ The outer brake pads have an adhesive foil on the pad backing plate. Remove the protective foil before inserting.
Note: The pads are marked with an arrow. The arrow must point in the direction of forward rotation of the brake disc when installed. Noises may result from Incorrect installation.
12. Brake disk
^ Pads on both sides of axle must always be replaced together.
^ Check for sufficient wear limit.
^ Remove brake caliper before removing
As of implementation of the combination sport suspension 8J x 18 wheel! the brake caliper housing of the front brake is equipped with an additional bracket (for all vehicles). If the 8J x 18 wheel is retrofitted and there is no bracket at the brake caliper housing, retrofit according to illustration.
1. Retaining spring
2. Bracket
^ Bolt to brake caliper housing
^ Insert harness connector for brake pad wear indicator
3. Brake line, 15 Nm
4. Hex bolt, 25 Nm
^ Do not tighten until bracket -6 - is secured using the gap bracket -5-.
5. Gap bracket
^ Secures the installation position of retaining bracket and brake line.
6. Retaining bracket
^ Bolt to brake caliper housing
^ Note marking: L = left side, R = right side
7. Brake hose
^ Do not unscrew brake pads when removing
Brake pads, removing and installing
Removing
Note: When removing, mark brake pads that will be used again. Install in the same position, otherwise braking effect will be uneven!
- Raise vehicle.
- Remove wheels.
- Secure brake disk using a wheel bolt.
- Unscrew both Torx bolts for the outer brake pads.
Note: Before pushing back the piston, siphon some of the brake fluid out of the brake fluid reservoir. Otherwise, especially if reservoir has been topped off, fluid will overflow and cause damage.
WARNING: Brake fluid is poisonous. NEVER siphon brake fluid with your mouth!
- Press piston back into brake caliper housing.
- To do this, insert floating frame using a screwdriver as shown and press powerfully outward.
- First remove outer brake pad, press brake pads off brake caliper for this using a screwdriver.
- Disconnect harness connector, press spring for this and disconnect connector.
- Remove wire for brake pad wear indicator from bracket at brake caliper.
- Carefully lift alignment tab slightly at lower part of connector using a screwdriver, then turn 90° toward left or right and remove from bracket.
- Press floating frame powerfully in direction of arrow until stop.
- Carefully press brake pads out of piston using a screwdriver and remove brake caliper housing.
Note:
Clean brake caliper housing thoroughly before installing new brake pads.
Be especially careful to remove any residual adhesive foil, left by outer brake pads.
Installing
- Insert/press in brake pad with wire for wear indicator in upper piston.
Note: Do not damage protective caps when installing brake pads.
- Insert lower brake pads in piston.
- Clip wires for brake pad wear indicator into bracket at brake caliper.
- Insert lower part of connector for brake pad wear indicator into bracket at brake caliper.
- Press floating frame outward until stop.
- Remove protective foil on backing plates of outer brake pads.
Note:
^ The arrows on the brake pads point toward front of vehicle and in direction of brake disk rotation when driving forward.
^ The springs -1- must be engaged in the gaps at brake caliper.
Note:
^ Repair kit includes four self-locking Torx bolts which must always be installed.
^ After replacing brake pads and before moving vehicle, always depress brake pedal several times firmly to properly seat brake pads in their normal operating position.
- Install the Torx bolts included in the repair kit into the floating frame and secure brake pads.
^ Tightening torque: 25 Nm
- Remove wheel bolt from wheel hub.
Note:
When installing wheels, be sure rim flange does not rest on brake caliper.
This could push brake pads out of position.
- Tighten wheels to 120 Nm when installing.
- Check brake fluid level and top off, if necessary.