Iveco Daily. Manual

Re-assembly

Check wear of brake liners and safety springs.
Replace the parts which are either deformed or
worn.

It is recommended to replace the piston dust covers
and seal rings even if they do not show any signs of
deformations or defects.

When washing the metal components use hot water
with Fiat LCD type detergent.

By means of a metal brush, remove any dirt from the
brake caliper, then eliminate any residual dirt with
the use of a brush. Carefully clean the seats of the
guide pins, sliding bushes, pistons and the pistons
themselves.

By means of a suitably sized synthetic brush, remove
all traces of grease from the seats of the sliding
bushes. Open the bleeder valves, then carefully blow
compressed air into the brake caliper casing.

By means of a piece of canvas soaked in methylated
spirits or similar, carefully clean the sliding surfaces.

Check the wear on the sliding bushes, pistons and
relevant seats on the brake caliper casing. Make sure
that the sliding surfaces are neither damaged or
worn.

Insert the bushes and pistons into the seats and
check that they are free to slide, otherwise restore
or replace as necessary.

45035

Remove the seal rings (1) from the brake caliper cylinder
seats.

Cleaning and checking of main components
For all types of brake calipers

A regular braking effect depends a great deal on the
condition of the sliding surfaces.

45035

Insert the seal rings (1) into the relevant seats of the caliper
casing.

Lubricate the pistons and seal rings with brake liquid
Tutela DOT SPECIAL.

Figure 70

Figure 71

Insert the dust boots (4 and 5) in their seat on the brake
calliper (1). Fit the cylinders (2) and the sliding bushings (3)
and make sure they slide freely.

Correct sliding if required by lubricating the bushings with
Klueber glk1pf grease.

Insert the dust covers into the relevant sears on the pistons
(2) and on the sliding bushes (3).

Figure 72

45036

1x52 Brembo brake calipers

The 1x52 callipers (rear, 29 L - 35 S vehicles) are
equipped with an automatic brake liner wear
tensioner device and the components cannot be
removed.
Consequently, replacement/overhauling operations
on the piston, dust boot and internal components
must only be carried out by specialised personnel.
Only the sliding bushings can be overhauled. The
removal/refitting procedure is the same as that
described for the other callipers.

HYDRO-PNEUMATIC SYSTEM - BRAKES

AILY

Base - May 2004

To take down and fit back the brake disk (1) follow the
procedures described in the “axles” section.

Check the wear on the surfaces of the drum brakes.

When values different from those indicated in the
specifications and data table are found, machine and grind the
disk brakes and, if necessary, replace them.

45038

527411

OVERHAULING BRAKE DISCS

Figure 73

- Fit the disk brake (1) complete with the wheel-hub to

the late arbor 99301005 (2);

- fit a set of spacers on the shaft to remove unit end play,

tighten the lock nut and apply the lathe support;

- place the tool-holder (3) along the axis of the drum

brake (1) then adjust the work depth of the tools;

- turn down the drum brake (1) by passing over the

surface a few times depending on the condition of the
surface itself.

45039

45040

By means of the lathe 99301001 (1), machine both working
surfaces of the drum brake.

527411

MACHINING AND GRINDING OF
DISC BRAKES

During this grinding operation, gradually move the
sequential wheel towards the working surface in
order to completely remove the swarf left over from
turning.

Figure 74

Figure 75

HYDRO-PNEUMATIC SYSTEM - BRAKES

AILY

Base - May 2004

Remove shoe retaining pins (3) and parking brake wire
hitching device (4).

45049

Disjoin support (1) and withdraw sensor (2) to
remove ABS sensor (2).

To reassemble the sensor (2), push it as far as it will
go inside support (1) and fasten the latter to the rear
axle.

Release shoe (1) return springs (2 and 5). Save the adjusting
device (3).

Remove retaining brackets (4 and 6) and detach shoes (1).

45048

52746

52747

Figure 76

Figure 77

Figure 78

Figure 79

Dismantling parking drum brake

OVERHAULING PARKING BRAKE

WHEEL NUT TIGHTENING SEQUENCE

5817 - 450210 AXLE TIGHTENING ORDER

Tighten the screws at the specified torque in the order
shown.

AXLE TIGHTENING ORDER

(EXCEPT FOR 5817 AND 450210)

Tighten the screws at the specified torque in the order
shown.

NOTE

HYDRO-PNEUMATIC SYSTEM - BRAKES

AILY

Base - May 2004

Check inner disc diameter to establish whether it can
be reused.
Measure the inner disc diameter with a sliding gauge
without moving the arms to an angle.
Measure the drum diameter in several spots to
determine ovality and wear. Also examine depth of
scoring on the braking surface.
Max permitted ovality and/or eccentricity tolerance
is 0.1 mm.

Replace the disc if wear or evident signs of overheating are
found (see specifications and data table).

Figure 80

VIEW OF THE PARKING DRUM BRAKE

For models 35C - 40C - 45C - 50C

Check brake jaw conditions and replace if anomalies are
found.
If the brake lining surface is oily, trace the cause and repair the
fault.
The minimum brake seal thickness is 3.5 mm for models 60C
- 65C, and 1.5 mm for models 35C - 40C - 45C - 50C.
If this is not so, even if only slightly above or below the
specified value, replace them.
Check serviceability of shoe return springs.

62674

45047

VIEW OF THE PARKING DRUM BRAKE

Figure 81

For models 60C - 65C

HYDRO-PNEUMATIC SYSTEM - BRAKES

AILY

Base - May 2004

Content .. 335 336 337 338 ..

Iveco Daily. Manual - part 337