Lubricating the Brake Caliper Slide Rail, Bosch Hydraulic Brakes

sb mm 42.13.001

Warning: Breathing brake lining dust (asbestos or non-asbestos) could cause lung cancer or lung disease. Unless exposure can be reduced below legal limits, wear an air purifying respirator approved by MSHA or NIOSH at all times when servicing the brakes, starting with removal of the wheels and continuing through assembly.

Important: Lubricate every 6 months or every 18,000 miles (28 800 km), whichever comes first.

  1. Park the vehicle on a level surface. Shut down the engine, set the parking brake, and chock the front or the rear tires, depending on which axle you are working on.
  2. Raise the vehicle off of the ground and securely support it with jack stands.
  3. Remove the wheel from each wheel end. For instructions, see General Information, Wheels and Tires of the Shuttle Bus Chassis Workshop Manual, or take the vehicle to an authorized Freightliner dealer.
  4. Place a stool near the axle to rest the caliper on after it is removed.
  5. Remove the key-retaining fastener from the anchor plate. See Fig..

    1. Caliper

    2. Wear Shim

    3. Spring

    4. Fastener

    5. Key

    6. Anchor Plate

    Fig. 1, Anchor Plate and Key Fastener

  6. Using a hammer and drift, carefully drive out the key and spring. See Fig.. Be careful not to nick the anchor plate rail.

    1. Key

    2. Spring

    3. Anchor Plate Upper Rail

    4. Rotor

    5. Outboard Brake Pad

    6. Caliper Housing

    Fig. 2, Driving Out the Key and Spring

  7. Insert a large flat-bladed screwdriver through the caliper vent window and into the rotor fins. Pry the caliper outward; this will push the pistons back slightly into the caliper, making removal easier.
  8. Grasp the caliper, swing it out and lift it from the anchor plate. Rest the caliper on the stool. For ease of removal, swing the caliper on the forward anchor plate torque rail (the large one opposite the key and spring rail).
  9. Carefully remove the brake pads to avoid damaging them or getting grease on the pad faces. Set them aside.
  10. Using brake cleaner or alcohol, remove old grease and road accumulation from the caliper V-ways, the anchor plate rails, and the shoe slots. Also clean the key and spring. See Fig. and Fig..

    1. V-Ways

    2. Bleeder Fitting

    Fig. 3, Caliper V-Ways

  11. Using a wire brush or wire wheel, remove any remaining debris from the V-ways, rails, shoe slots, key, and spring.
  12. Inspect the caliper and ensure that the piston boots are in good condition with no punctures or tears, and that they are properly seated in the caliper. Check to see that the heat shields are properly seated. Repair or replace them if necessary.
  13. Inspect the brake hoses for twists, cracks, blisters, or abrasions, and replace them if necessary.
  14. Apply two level teaspoons of Aeroshell Grade 5 (ES–1246) grease on each side of the assembly. Apply it evenly along the full length of the V-way groove and anchor plate rail, and apply one level teaspoon evenly on both sides of the key and spring. After the caliper is installed, pack any accumulation of grease at each end of the rail and along the top of the rail or key at the V-way.
  15. Being careful not to get grease or dirt on the pad face, reinstall each brake pad.
  16. Grasp the caliper firmly, rest the V-ways on the forward anchor plate torque rail (the large rail), and swing the caliper into place. Make sure that the brake hose is not twisted. Do not get grease on the pad faces or rotor surfaces.
  17. With the caliper installed and firmly seated on the forward rail (large rail), position the key and spring between the caliper V-way and the anchor rail from the in-board end of the anchor rail.
  18. Carefully drive the key and spring into place. Install the key-retaining fastener and torque it 12 to 18 lbf·ft (16 to 24 N·m).
  19. Install the wheels. For instructions, see General Information, Wheels and Tires of the Shuttle Bus Chassis Workshop Manual.
  20. Before moving the vehicle, press the brake pedal several times to bring the pistons back to the normal position.
  21. Raise the vehicle, remove the jack stands, and lower the vehicle to the ground.
  22. Remove the chocks from the tires.
  23. Test drive the vehicle and ensure that the brakes operate properly.
Note:
Parent topic: Brakes
Document Number: 0000120765
Manual Publication Date: 2025-01-08
Topic Publication Date: 2025-01-08