Iveco Daily. Manual

Figure 52

Figure 53

Figure 54

Figure 55

We suggest that both brake discs be renewed also
in case one of them only needs to be replaced.
As regards brake lining

pairs, always replace a

complete series for each axle.

Always overhaul both brake calipers also in case one
of them only seems to be damaged.

Inspect the state of the dust caps. If they are out of shape or
broken, it is necessary to replace them. Remove the dirt from
the brake caliper with a wire brush, without damaging the
dust caps. Check the surfaces of the brake disc and make sure
there is no corrosion or scoring. Small surface cracks are
acceptable, but it is then necessary to grind the brake disc as
described under the relevant heading. Replace worn brake
discs.

Be careful not to damage the surface of the pistons
and the protective boots in contact with the tool.

Clean the pad resting surface with suitable materials and
products (e.g. with a damp cloth). Avoid using nitro thinner
or petrol, etc., which could damage protective boots.

79526

Insert new brake liners (1) in the brake calliper mount and
check that they slide in their seats.

Use a torque wrench (3) to tighten the screws (1) at the
specific torque.
Connect the wear sensor connection (2).

The screw (1) is treated with threading locking
adhesive, therefore every time the screw (3) is
removed it must be changed.

46487

52272

Fit on the protective rubber plug (1).

52273

527413

Brake caliper removal and refitting

Removal

For 2x42 calipers

Remove the protective rubber plugs (1 and 2).

HYDRO-PNEUMATIC SYSTEM - BRAKES

AILY

Base - May 2004

Check the pistons are fully retracted inside the
caliper body.

Refit by carrying out the operations described for
removal in reverse order, observing the required
tightening torques.

Every time the screws (1 and 5, Figure 56) are
removed, they must be replaced.

Disconnect the lining wear sensor electrical connection (2).
Disconnect the pipe (3) from the caliper (4) and drain off the
brake fluid.
Unscrew the screws (1 and 5) and remove the brake caliper
(4).

Set the vehicle on level ground, loosen the nuts (1) securing
the wheels.
Lift the front of the vehicle with a hydraulic lift and rest it on
two stands (2).
Unscrew the nuts (1) and remove the wheels.

45045

52274

For all brake calipers

Refitting

527440

REAR BRAKES

The following operations have been carried out on vehicles
with 2x44 and 2x46 Brembo rear calipers.
They should be considered similar also for 1x52 Brembo rear
calipers unless stated otherwise.

527447

Replacing brake linings

Figure 56

Figure 57

Drive slowly without prolonged, sudden brake
application during the first period of use of new
brake pads because braking efficiency is reduced.

Press the brake pedal repeatedly to restore pressure in the
system and correct brake pedal stroke.

46849

Figure 58

Remove the brake linings (1).

Retract the pistons are shown in Figure 51.

Disconnect the wear sensor connection (2). Unscrew the
screws (1) and turn the brake caliper (3) over.

If the liners are replaced in vehicles with leaf spring
suspensions, extract both bushings and entirely separate the
calliper body from the mount.

50734

Figure 59

Remove the protective rubber plug (1).

For 1x52 calipers

For all brake calipers

46287

Figure 60

HYDRO-PNEUMATIC SYSTEM - BRAKES

AILY

Base - May 2004

We suggest that both brake discs be renewed also
in case one of them only needs to be replaced.
As regards brake lining

pairs, always replace a

complete series for each axle.

Always overhaul both brake calipers also in case one
of them only seems to be damaged.

46850

Fit the new linings (1) to the brake caliper mounting. Ensure
linings are free to slide in their seats.

Push brake caliper pistons (2) as far as they can go. Then
position the caliper on the brake linings.

Figure 61

For 1x52 calipers

51223

Figure 62

Using tool 99372236 (1) retract the piston (3) by pushing
constantly in line with the piston axis with a force of approx.
300

÷ 400 N while turning the tool clockwise until the piston

(3) is fully retracted.

During this operation, take care not to twist the
protective cap (2) or let it swell out.

Let the air out of the cap by moving it away from the
brake caliper.

Inspect the state of the dust caps. If they are out of shape or
broken, it is necessary to replace them.

Remove the dirt from the brake caliper with a wire brush,
without damaging the dust caps.

Clean the pad resting surface with suitable materials and
products (e.g. with a damp cloth). Avoid using nitro thinner
or petrol, etc., which could damage protective boots.

Check the surfaces of the brake disc and make sure there is
no corrosion or scoring. Small surface cracks are acceptable,
but it is then necessary to grind the brake disc as described
under the relevant heading. Replace worn brake discs.

For all brake callipers

Tighten the screw (3) to the required torque with a torque
wrench (1).
Connect the wear sensor connection (2).

Figure 63

Figure 64

46290

For 1x52 calipers

50734

Fit on the protective rubber plug (1).

Drive slowly without prolonged, sudden brake
application during the first period of use of new
brake pads because braking efficiency is reduced.

Press the brake pedal repeatedly to restore pressure in the
system and correct brake pedal stroke.

For all brake callipers

The screw (1) is treated with threading locking
adhesive, therefore every time the screw (3) is
removed it must be changed.

HYDRO-PNEUMATIC SYSTEM - BRAKES

AILY

Base - May 2004

Figure 65

527443

Brake caliper removal and refitting

Removal
For 1x52 calipers

51753

Remove the protective rubber plugs (1 and 2).

For all brake calipers

Remove the retaining clip (1) and unhook the parking brake
rope.

Every time the screws (1 and 4, Figure 66) are
removed, they must be replaced.

Refit by carrying out the operations described for
removal in reverse order, observing the required
tightening torques.

Removal

Disconnect brake shoe wear sensor electrical connection (3).
Disconnect the calliper (5) hose (2) from the pipe with a
suitable tool (cap the pipe to prevent leakage of brake fluid).
Loosen the screws (1 and 4) and remove the brake calliper
(5).

46046

Figure 66

50735

Figure 67

For 1x52 calipers

Replace the hose if anomalies are found.

Remove the hose at the bench.

Place the caliper on a work bench. Insert a block of wood (2)
so that the pistons can be removed without damaging them,
and to make the operations safe for the technician.

By means of a gun (3), introduce air into the brake caliper the
pistons (1) are extracted.

Remove the dust boots from the respective seats.

45033

45034

Figure 68

Figure 69

Remove the dust covers (1 and 2) and keep the sliding bushes
(3).

527413

OVERHAUL OF BRAKE CALIPERS

2x42 - 2x44 - 2x46 - 2x52 Brembo brake calipers

Disassembly

NOTE

HYDRO-PNEUMATIC SYSTEM - BRAKES

AILY

Base - May 2004

Content .. 334 335 336 337 ..

Iveco Daily. Manual - part 336