Brake Job Execution Matrix

⚠️ SECURITY FIRST: Jack stands on reinforced pinch welds. Keep hydraulic jack slightly raised under axle as fail-safe.

Tools & Hardware

Tool	Purpose
YATO YT-1714	Small bolts (12 - 32 Nm)
Big Torque Wrench	Bracket & Wheels (80 - 180 Nm)
PASSK 20-Li C4 Impact	Wheel removal
Anti-slip Chocks	Front wheels (both directions)
Vacuum / Brushes / Mallet	Cleaning and handling

Chemicals Matrix

Product	Target
MA PROFESSIONAL	Caliper slider pins ONLY (Hazelnut size)
Wurth HT	Pads, clips, star-wheel, handbrake hinge, hub face
K2 PROLOK T245	Main bracket bolts (1 drop per bolt)
PTFE Sprej	Handbrake cable sleeve, return spring
Coyote Biela lítiová	Door hinges/latches
Acetone-Free Cleaner	General decontamination

Execution Phases

1. Preparation

Place wheel chocks on front wheels securely.
Wrap clean rag around brake fluid reservoir base.
Loosen brake fluid reservoir cap.
Ensure handbrake lever is completely disengaged.

2. Disassembly 🎬 [00:00:26]

Remove caliper, bracket, and brake disc.
Wire brush metal surfaces.
Vacuum dust.
Spray Acetone-Free Brake Cleaner.
Clean accordion rubber boots with mild soapy water.

3. Pin Overhaul🎬 [00:19:07]

Pull rubber-booted slider pins from bracket.
Clean out old grit.
Coat pins and inside of boots with MA Professional (hazelnut size).

4. Pivot Lubrication🎬 [00:24:25]

Inspect handbrake cable under rubber boot.
Blast PTFE spray down cable sleeve.
Check return spring for vigorous snap-back.
Spray PTFE into cup, paint exposed spring coils.
Dab Wurth HT strictly inside spring hook anchor holes.
Spray Wurth HT into cap, dab swab, apply deep into backing plate hinge.

5. Bracket Securing🎬 [00:30:41]

Apply exactly 1 drop of K2 PROLOK T245 per main caliper bracket bolt.
Tighten main bracket bolts to 160 - 210 Nm.

6. Pad Installation🎬 [00:39:41]

Spray Wurth HT into cup.
Paint bracket where metal clips touch.
Install metal clips and paint them.
Smear Wurth HT lightly across metal backs of pads.
Install pads and caliper. Tighten slider pin bolts to 32 Nm.

7. Pre-Ground Testing

Pull handbrake lever up 3 to 4 clicks.
Attempt to spin repaired wheel by hand (Should lock).
Put torque wrench on wheel lug bolt set to 80 Nm. Wrench should click without wheel spinning.
Mount wheel fully. Tighten wheel lug bolts to 180 Nm.
Tighten brake fluid reservoir cap.
Lower van to ground.
Pump foot brake pedal 10 times firmly.

8. Bedding & STK Prep

Bedding: Drive 15-20 km/h, pull handbrake gently 3-5 seconds (drag only). Repeat 3 times.
Gravel Test: Drive 5-10 km/h on gravel, shift neutral, yank handbrake. Verify two equal skid marks.

Misc Tasks

Doors: Blast latches/hinges with Brake Cleaner, inject Coyote Biela lítiová.
Throttle Body: Spray Wurth HT on M6x50 bolts, wait 60s, install.