Rear with PCCB
Removing and installing rear PCCB brake disc
Preliminary work
Removing PCCB brake disc
1. Remove wheel. Use assembly aids (assembly pins) -1-.
PCCB brake disc with rear-axle calliper and assembly aids 1 (threaded bolts for fitting wheel)
Removing rear brake disc
Notice
Removing/fitting wheels
Risk of damage to (ceramic) brake discs
- Use two assembly pins when removing and fitting the wheel.
- Carefully guide the wheel towards the wheel hub, thereby preventing any heavy impact on the (ceramic) brake disc.
1. Screw the two assembly aids (assembly pins) -1-, instead of two wheel bolts, into the wheel hub before removing/fitting the wheel. During removal, first remove the three remaining wheel bolts and remove the wheel carefully without touching the brake discs.
PCCB brake disc with rear-axle calliper and assembly aids 1 (threaded bolts for fitting wheel)
2. Then (after removing the wheel), remove the two assembly aids (assembly pins) -1- again.
3. Disconnect plug connection for brake pad wear indicator on wheel carrier.
4. Remove screw plug -arrow-. The adjustment fixture can be twisted through this bore.
Bore for adjustment fixture
5. Turn the brake disc in such a way that the adjustment fixture becomes visible. Insert a screwdriver through the bore and turn the adjustment device towards "release".
Setting adjustment device
6. Set the brake pads back slightly and uniformly using water pump pliers.
7. Remove the brake calliper from the wheel carrier and hang it in a suitable place in the wheel housing (do not open brake hydraulics!). First, pull out the electric wires on the brake calliper holder and the brake pad wear wire on the wheel carrier holder.
8. Remove the fastening screw and take off the brake disc.
Explanation of 2-part brake disc
1. The PCCB brake discs consist of two parts on the front and rear axles. The brake disc -1- is screwed to the brake-disc chamber -2- with 10 screws (M6) -3-.
2. Only the complete brake disc is available as a spare part (disc + brake-disc chamber)!
3. Do not separate the brake-disc chamber -2- and brake disc -1-. In addition, the screws -3- must not be turned and should not need to be turned. The screws are prevented from turning by compression in the bushing.
4. It is essential that the tightening torque of the 10 screws is not changed (do not turn the screws) as this will have a negative effect on the sound behavior.
Installing rear brake disc
Information
Always replace the brake calliper fastening screws following removal!
Do not confuse right and left brake discs during assembly!
Distinguishing characteristic: Part No.! The flat surface of the brake discs is marked with R = right or L = left.
1. Check that all parts are in perfect condition and replace them if necessary.
2. Clean the levelling and centering surfaces on the brake disc and wheel hub. Then apply a very thin coat of Optimoly TA to the centering surface on the wheel hub.
3. Fit the brake disc. Observe tightening torque.
4. Fit the brake calliper. Observe tightening torque.
5. Adjust the brake shoes of the foot-operated parking brake with a screwdriver.
Setting adjustment device
6. Position disc brake pads by operating the brake several times.
7. Check brake fluid level and correct it if necessary. The brake fluid level must be within the MIN/MAX marking.
Marking on brake fluid reservoir
Subsequent work
Fit the wheel. Use assembly aids (assembly pins) -1- (-1-).
PCCB brake disc with rear-axle calliper and assembly aids 1 (threaded bolts for fitting wheel)
Information on bedding in new brake pads
New brake pads require a slightly longer bedding-in period for PCCB brake discs than cast iron brake discs.
In general, the following applies: New brake pads must be worn in (bedding-in period). Their optimum braking effect is therefore not reached until after a few hundred kilometers. The slightly reduced braking effect must be compensated for by increased pressure on the brake pedal. The same also applies after changing brake discs.