Brake systems

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Technical data for brakes
  1
• 2 Brake test
  2
• 2.1 General information
  2
• 2.2 Checking vehicles with rear-wheel drive
  2
• 2.3 General notes on brakes for Crafter 4MOTION with Achleitner four-wheel drive
  2
• Anti-lock brake system
  3
• 1 General information
  3
• 1.1 General notes on ABS
  3
• 1.2 Repair instructions for repair work on ABS
  3
• 1.3 Fault display via warning lamps
  5
• 2 Overview of fitting locations
  7
• 2.1 Overview of fitting locations - ABS/ESP
  7
• 3 Control unit and hydraulic unit
  14
• 3.1 Assembly overview - control unit and hydraulic unit
  14
• 3.2 Removing and installing ABS control unit J104 and ABS hydraulic unit N55
  18
• 3.3 Connecting brake lines to hydraulic unit
  24
• 4 Sensors
  25
• 4.1 Assembly overview - speed sensor on front axle
  25
• 4.2 Assembly overview - speed sensor on rear axle
  26
• 4.3 Removing and installing speed sensor wire on front axle
  28
• 4.4 Removing and installing speed sensor wire on rear axle, Crafter 3.0 t and 3.5 t
  30
• 4.5 Removing and installing speed sensor wire on rear axle, Crafter 5.0 t
  31
• 4.6 Removing and installing wire for brake pad wear indicator on front axle
  32
• 4.7 Removing and installing wire for brake pad wear indicator on rear axle
  33
• 4.9 Removing and installing steering angle sender G85
  34
• Brakes - mechanism
  35
• 1 Front brakes
  35
• 1.1 Assembly overview - front brakes
  35
• 1.2 Removing and installing brake pads/linings
  36
• 1.3 Removing and installing brake caliper
  38
• 1.4 Removing and installing brake disc
  40
• 2 Rear brakes
  43
• 2.1 Assembly overview - rear brake, Crafter 3.0 t and 3.5 t
  43
• 2.2 Assembly overview - rear brake, Crafter 5.0 t
  45
• 2.3 Assembly overview - brake shoes for handbrake, Crafter 3.0 t and 3.5 t
  47
• 2.4 Assembly overview - brake shoes for handbrake, Crafter 5.0 t
  48
• 2.5 Removing and installing brake pads, Crafter 3.0 t and 3.5 t
  48
• 2.6 Removing and installing brake pads, Crafter 5.0 t
  51
• 2.7 Removing and installing brake caliper, Crafter 3.0 t and 3.5 t
  53
• 2.8 Removing and installing brake caliper, Crafter 5.0 t
  55
• 2.9 Removing and installing brake carrier
  57
• 2.10 Removing and installing brake disc
  58
• 2.11 Removing and installing brake shoes for handbrake, Crafter 3.0 t and 3.5 t
  60
• 2.12 Removing and installing brake shoes for handbrake, Crafter 5.0 t
  62
• 3 Parking brake
  65
• 3.1 Assembly overview - handbrake lever
  65
• 3.2 Removing and installing handbrake lever
  66
• 3.3 Removing and installing front handbrake cable
  67
• 3.4 Note on adjusting handbrake
  67
• 3.5 Adjusting front handbrake cable
  67
• 4 Brake pedal
  71
• 4.1 Assembly overview - brake pedal
  71
• 4.2 Removing and installing brake pedal
  71
• Brakes - hydraulics
  73
• 1 Front brake caliper
  73
• 1.1 Assembly overview - front brake caliper
  73
• 1.2 Removing and installing front brake caliper piston
  74
• 2 Rear brake caliper
  76
• 2.1 Assembly overview - rear brake caliper, Crafter 3.0 t and 3.5 t
  76
• 2.2 Assembly overview - rear brake caliper, Crafter 5.0 t
  77
• 2.3 Removing and installing rear brake caliper piston, Crafter 3.0 t and 3.5 t
  77
• 2.4 Removing and installing rear brake caliper piston, Crafter 5.0 t
  79
• 3 Brake servo and brake master cylinder
  82
• 3.1 Assembly overview - brake servo/brake master cylinder
  82
• 3.2 Removing and installing brake light switch F
  83
• 3.3 Removing and installing brake servo
  84
• 3.4 Removing and installing brake master cylinder
  85
• 4 Vacuum system
  87
• 4.1 Checking non-return valve
  87
• 4.2 Removing and installing vacuum pump
  87
• 5 Brake lines
  88
• 5.1 Assembly overview - flanging tool
  88
• 5.2 Notes for repairs to brake lines
  89
• 5.3 Repairing brake lines
  90
• 5.4 Additional brake line on Crafter 4MOTION with Achleitner four-wheel drive
  92
• 6 Hydraulic system
  94
• 6.1 Bleeding hydraulic system following standard procedure
  94
• 6.2 Testing for leaks
  95