2026-01-16

Replacing Powerwall Dolly Brake Assembly

Safety and PPE

Safety glasses (ANSI Z87.1 or EN 166)
Cut-resistant gloves (ANSI Cut Level 3 or EN 388 Level C)

General Equipment

5 mm Hex bit
T25, T30, T40 Torx bit
Quick-Grip clamp
Adjustable wrench
Torque wrench (capable of 6 Nm, 10 Nm, and 16 Nm)

Required Parts and Tools

Spare brake kit (2292985-00-A)
- Powerwall Dolly brake (2072311-00-C: ASSY, MAGURA MT BRAKE, POWERWALL DOLLY) - 1
- M6 Screws (2135918-00-A: THREAD LOCKING SHCS, M6 X 1.25MM) - 4
- Spacer (2135919-00-A: SPACER 13MM OD X 6.3MM ID) - 4

Remove Old Brake Assembly

Use a T25 Torx bit to remove the two bolts securing the brake handle to the Powerwall Dolly.

Remove the brake handle.
When working with the older versions of the Powerwall Dolly (-B through -E), you must remove the dolly handle before you can slide off the brake handle.
1. Use a T30 Torx bit to remove the four bolts securing the dolly handle to Powerwall Dolly. Remove the dolly handle.
  
  CAUTION
  Retain all hardware for use during installation of the new brake assembly.
2. Use a T30 Torx bit to remove the bolt securing the brake handle to the dolly handle and slide it off.
  
  Note
  You can use a flathead screwdriver to gently pry open the component and create a larger gap, allowing the handle to slide off more easily.
3. Reinstall the dolly handle, using a T30 Torx bit to tighten the 4 bolts.
  
  Torque the bolts to 6 Nm.
Remove the P clamps from the upper handles of the dolly to release the brake assembly cables.

Use a 5 mm Hex bit to unfasten the lower bolt on the right handle (1) and the upper bolt on the left handle (2) to remove the P clamps.

CAUTION
Retain all hardware for use during installation of the new brake assembly.
Unclip the brake assembly cables from the clips highlighted below.

Make sure that the clips remain on the Powerwall Dolly in this step.
Use a T40 Torx bit to remove the two bolts securing the P clamps near the lower handles of the dolly. Remove the P clamps.

CAUTION
Retain all hardware for use during installation of the new brake assembly.
When working with the older versions of the Powerwall Dolly (-B through -E), remove the lower handles of the dolly first to gain better access to the P clamps.
1. Use a T40 Torx bit to remove the two bolts securing each lower handle to the dolly (four in total). Remove the lower handles.
  
  CAUTION
  Retain all hardware for use during installation of the new brake assembly.
2. Use a T40 Torx bit to remove the two bolts securing the P clamps on both sides. Remove the P clamps.
  
  CAUTION
  Retain all hardware for use during installation of the new brake assembly.
Use a 5 mm Hex bit to remove the two M6 bolts (highlighted) securing the brake to the dolly.

Repeat on the opposite side.

Install New Brake Assembly

Note

Compatibility Note: For older Powerwall Dolly versions (with 160 mm wheel brake rotor):

To ensure compatibility with the new brakes, you must replace the existing 160 mm brake rotor with the new 180 mm brake rotor. Order Brake Rotor Spares, PW Dolly: 2293137-00-A, which supplies two 180 mm brake rotors.

Failure to do so may result in the failure of the brake assembly.

Refer to Replacing the Brake Rotor procedure for detailed replacement instructions.

Use a T25 Torx bit to fasten the two bolts securing the new brake handle to the dolly handle. Install the brake handle in a comfortable, ergonomic position. Adjust the position of the brake handle to ensure there is no interference between the brake lever and the dolly handle, as shown below.

Torque the bolts to 3 Nm.

CAUTION
Do NOT squeeze the brake handle before mounting the brake calipers on the rotors.

CAUTION
Do not over torque the bolts, as this can result in component failure.

CAUTION
Torque both bolts equally. Torquing one bolt more than the other can result in deforming the brake handle assembly as shown below (right).
Position the brake calipers as shown, making sure they loop behind the handles to improve cable management.
Identify and differentiate the left and right calipers based on the images below.

Make sure that the two T25 bolts on both calipers are loose to allow for movement during installation.
Begin by installing the left caliper first.

Place the provided spacers on the side closest to the wheel (1).

Use a 5 mm Hex bit to fasten the provided M6 screws and mount the brake caliper on the mounting holes (2).

Torque the screws to 10 Nm.
Repeat for the brake calipers on the right side.

Place the provided spacers on the side closest to the wheel (1).

Use a 5 mm Hex bit to fasten the provided M6 screws and mount the brake caliper on the mounting holes (2).

Torque the screws to 10 Nm.
Once both brake calipers are mounted on the rotors, use a clamp to depress the brake lever, allowing the calipers to self-align.

CAUTION
Do NOT depress the brake lever before mounting the brake calipers on the rotors.

Note
It is not necessary to fully compress the lever.
With the brake lever depressed, use a T25 Torx bit to fasten the two bolts on each caliper and torque them to 6 Nm.

Release the clamp from the brake lever after this step.
Start with the left handle. Place the P clamp over the upper bolt (1) and use a T30 Torx bit to fasten the bolt and secure the P clamp to the handle (2).

Torque to 10 Nm.
Repeat on the right handle. Place the P clamp over the lower bolt (1) and use a T30 Torx bit to fasten the bolt and secure the P clamp to the handle (2).

Torque to 10 Nm.
Adjust the brake assembly cables, ensuring they are straight and free of kinks or deformation.

Press the cables into the clips highlighted below.
Locate the T40 bolts toward the bottom of the dolly, one near each of the lower handles as shown.

Place the P clamp over one of the bolts (1) and use a T40 Torx bit to fasten the bolt and secure the P clamp to the dolly (2).
Torque to 16 Nm.

Repeat on the other side.