BELGIEN

Haldex N.V./S.A.
Brüssel
Tel +32 2 725 37 07
Fax +32 2 725 40 99
e-mail: [email protected]
BRASILIEN
Haldex do Brasil
São Paulo
Tel +55 11 5034 4999
Fax +55 11 5034 9515
e-mail: [email protected]
ENGLAND
Haldex Ltd
Newton Aycliffe
Tel +44 1325 310 110
Fax +44 1325 311 834
e-mail: [email protected]

Haldex Brake Products Ltd

Redditch
Tel +44 1527 499 499
Fax +44 1527 499 500
e-mail: [email protected]
FRANKRIKE
Haldex Europe S.A.
Weyersheim (Strasbourg)
Tel +33 3 88 68 22 00
Fax +33 3 88 68 22 09
e-mail: [email protected]
INDIEN
Haldex India Limited
Nasik
Tel

Fax
ITALIA SRL
+91 253 38 73 62
+91 253 38 73 63
+91 253 38 07 29 Haldex Disc Brake DB22
Muggiò
Tel +39 039 278 23 50
Fax +39 039 79 65 25
e-mail: [email protected]
KINA
Haldex International Trading Co. Ltd.
Shanghai
Tel
Fax
+86 21 6289 44 69
+86 21 6279 05 54
Service Manual
e-mail: [email protected]
POLEN
Haldex Sp.z.o.o.
Praszka
Tel +48 34 350 11 00
Fax +48 34 350 11 11
e-mail: [email protected]
SPANIEN
Haldex Espãna S.A.
Parets del Valles (Barcelona)
Tel +34 93 573 10 30
Fax +34 93 573 07 28
e-mail: [email protected]
SVERIGE
Haldex Brake Products AB
Landskrona
Tel +46 418 47 60 00
Fax +46 418 47 60 01
e-mail: [email protected]
SYDKOREA
Haldex Korea Ltd.
Seoul
Tel +82 2 2636 7545
Fax +82 2 2636 7548
e-mail: [email protected]
TYSKLAND
Haldex Brake Products GmbH
Denkendorf (Stuttgart)
Tel +49 711 934 9170
Fax +49 711 934 91740
e-mail: [email protected]

Haldex Brake Products GmbH

Heidelberg
Tel +49 6221 7030
Fax +49 6221 703400
e-mail : [email protected]
USA
Haldex Brake Products Corp.
Kansas City MO
Tel +1 816 891 2470
Fax +1 816 891 9447
e-mail: [email protected]
ÖSTERRIKE
Haldex Wien Ges.m.b.H.
Wien
Art.nr 89094/01-12/Landskrona

Tel +43 1 8 65 16 40
Fax +43 1 8 65 16 40 27
e-mail: [email protected]

Haldex is an innovator in vehicle

technology and supplies
proprietary products for trucks,
cars and industrial vehicles on a global
basis. Haldex is listed on the Stockholm Innovative Vehicle Technology
Stock Exchange and has annual sales Mark III
exceeding 6 billion SEK with 4,250
employees worldwide.
 1

Contents
Page
*Introduction .................................................................................................... 2
Product identification ............................................................................................ 2
Specifications .................................................................................................. 3
*Disc brake DB22 .................................................................................................. 3
*Tightening torques ............................................................................................... 4
*Wear limits ........................................................................................................... 4
*Description of operation ............................................................................... 5
*Recycling ........................................................................................................ 9
*Safety instructions ......................................................................................... 9
*Cleaning .......................................................................................................... 9
*Tools .......................................................................................................... 10
Maintenance .................................................................................................. 12
*Maintenance instructions................................................................................... 12
*Maintenance intervals ........................................................................................ 12
*Function test ...................................................................................................... 18
*Initial setting ....................................................................................................... 19
*Lubrication ......................................................................................................... 21
Service .......................................................................................................... 22
*Replacing radial seals (see ’Initial setting’) ........................................................ 19
*Replacing brake pads ........................................................................................ 22
*Replacing disc brake unit .................................................................................. 31
*Replacing bellows for adjustment screws ......................................................... 41
*Replacing slide pins, slide bearings and bellows .............................................. 50
Replacing mechanism ........................................................................................ 66
*Replacing brake chamber .................................................................................. 83
*Replacing spring brake chamber ....................................................................... 86
*Fault-finding ................................................................................................. 89
*Exploded view ......................................................................................... 91-92

Sections marked * are also appliable to earlier design

• Use appropiate spare parts documentation when obtaining spare parts.

• Use only genuine Haldex spare parts in repairs.
• Haldex reserves the right to make changes in the interest of technical progress.
• The contents of this manual are not legally binding.
• No part of this publication may by reproduced, copied or translated without the prior per-
mission of Haldex Brake Systems AB.
• This edition supersedes all previous editions of the same manual.
• Incase of a dispute between language versions, the english original takes priority.
2 Presentation

Introduction

Haldex disc brake is designed to provide high brake pad against the brake disc via two thrust
performance coupled with low weight, durability plates, which then causes the calliper to move (float)
and a minimum number of wearing parts. Floating laterally, activating the outer brake pad. The brake
brake callipers are used. Brake pad wear is calliper moves on slide pins. Where disc brakes have
compensated for by an automatic clearance a parking brake function, the mechanism is activated
adjustment mechanism. The mechanism, which is by a spring brake chamber.
activated by the brake chamber, presses the inner

1
(2)
3
4
5

Product identification
Type and serial numbers are stamped on an identification plate fixed to the calliper.
1. OEM/Haldex logo 5. Haldex S/N 1070324 (example)
2. OEM P/N (if required) 1 = year, 2001
3. Haldex EC (origin) 07 = week number.
4. Haldex P/N xxxxx 0324 = sequential number
 Specifications 3

Specifications
Disc brake DB22
Max. brake chamber force ....................................... 13.9 kN

Wheel size ................................................................. 22.5"

Number of actuating pistons ................................. 2

Number of slide pins ............................................... 4

Hysteresis (of complete brake) ............................... ≥10%

Threshold force (for brake assembly) .................... 28 N

Brake chamber stroke .............................................. min. 57mm, max. 65mm

Adjustment for excess clearance (see p. 5). ............ 15%

Mechanical ratio ....................................................... 15.8:1

Max. adjustment capacity ........................................ 58 mm

Pad thickness (friction material), new .................... 22 mm

Pad backplate thickness ........................................... 8 mm

Running clearance, brake pad to brake disc .......... 0.6 -0.9 mm

External diameter of brake disc .............................. 430 mm

Brake disc thickness, new ........................................ 45 mm

Effective radius ......................................................... 172.6 mm

Swept area, brake disc .............................................. 1808 cm2

Lining area (per pad) ............................................... 192cm2

Grease ....................................................................... Haldex P/N89652

Sealant ....................................................................... Haldex P/N89653

Anti-seize compound .............................................. Haldex P/N81934

Weight, disc brake, approx. ..................................... 41 kg (Without brake disc/pads/chamber and

wear sensor)

Wear sensor .............................................................. Optional

4 Specifications

Tightening torques
For number references in ( ) in the text which do not appear in this section, refer to the exploded view
(p. 91-92)

Bolts (22) for fixing disc brakes to axles.

Follow the vehicle/axle manufacturers recommendations or follow the method described below:

Step 1: Tighten to 100±5Nm (for all bolt sizes in the table below)

Step 2: Tighten to the number of degrees for the relevant bolt type as shown in the table below:

Angle tightening table M16* M18 M20

Pitch
1.0 mm +70° +70° +80°
1.5 mm +50° +50° +55°
2.0 mm +35° +35° +40°
2.5 mm - +30° +35°

Example: Bolt M 16 x 1.5 * = The bolt must not be

Tighten to 100±5 Nm + re-used
50°

Bolts for slide pins (10) (Torx) ................................ 220±20 Nm.

Fixing bolt (18) for mechanism in calliper ............. 20±3 Nm

Pad retainer bolt (8) ................................................. M10 45±5Nm

M8 20±3 Nm

(Cap nuts M6 ............................................................ 5±1 Nm)

Fixing bolts (27), brake chamber ............................ 180±20 Nm

Wear limits
Pads (5), min. lining thickness ................................ 2mm

Pads (5), max. uneven wear ..................................... 1mm

Slide pins (13), max. play ......................................... 1.0mm

Slide function, max slide resistance ........................ 100 N

Brake disc, min. thickness ....................................... 37mm

Brake disc, max. wear per side ................................ 4mm

Brake disc, max. lateral runout ............................... 0.5mm

Brake disc, max. thickness variation ...................... 0.1mm (DTV)

 Description of operation 5

Description of operation
For number references in ( ) in the text which do not appear in this section, refer to the exploded view
(p. 91-92)

Actuation/release of brake
47 63 68 66 67 62
During braking, lever (44) is actuated by brake
chamber (25/26). The inner section of lever (44)
presses the cross bar (41) axially towards the brake
disc (A). The force is transferred from the cross bar
(41) via adjustment screws (35/36) and thrust plates
(28) to the inner brake pad (5). As the brake pad (5)
comes into contact with the brake disc (A), the
▼ ▼ ▼
calliper (2) moves laterally on the slide pins (13) to
allow the outer pad (5) to contact the brake disc
(A). When the brake is released, return spring (38) 52
forces cross bar (41) back to its rest position,
allowing the design clearance between pad (5) and
brake disc (A) to be achieved.

Automatic adjustment
2 5 A 5 28 38 41 44 25/26
The brake operates in accordance with the clearance outer inner
principle. The braking sequence is split into three
phases: Design clearance C, Excess clearance Ce
(which is to be adjusted out) and Elasticity E.

Adjuster unit housing (62) is held in position against

the internal radius of lever (44) by a guide pin (47).
Adjuster unit housing (62) follows the movements
of lever (44). The rotational motion is transferred
from housing (62) to spring (63), which in turn
transfers the movement via companion sleeve (68)
to one-way spring (66), hub (67) and sychronisation
shaft (52).
6 Description of operation

Application
C - During the forward stroke through C, adjuster 63
unit (54) measures the design clearance between pads 68
(5) and brake disc (A). There is a pre-determined
clearance between hub (67) and sychronisation shaft 54
(52), which establishes the magnitude of the forward
stroke before the adjustment process begins. ▼

67 52

5 A 5 54

Ce - After mechanism (4) has moved axially through 54

clearance C, any clearance remaining, will cause 63
adjuster unit (54), synchronisation shaft (52), 62
pinions (51), crown wheels (57/58) and adjustment 68
screws (35/36) to turn. The rotation of the 66
adjustment screws (35/36) removes a percentage of
67
the measured excess clearance Ce.
▼
In adjuster unit (54), turning movement is transfer-
red from the housing (62) via adjustment spring (63),
companion sleeve (68), one-way spring (66) to hub
52
(67), which is engaged with synchronisation shaft
(52).

One of the two adjustment screws (35 and 36) is

left-hand threaded, whilst the other is right-hand
threaded.

52 54
 Description of operation 7

E - When pads (5) come into contact with brake 63

disc (A), the braking enters elasticity phase E, the
62
torque rises and adjuster unit (54) stops adjusting.
54
The continued rotational movement which now
occurs in adjuster unit (54) is allowed by rotating
housing (62) in relation to adjustment spring (63). ▼

To prevent tooth flank change, friction discs (50)

hold mechanism (4) under continuous pre-load.

5 A 5

Release
63
The first part of the return stroke is a combination
68
of elasticity phase, E, and design clearance C. Any
residual part of the return stroke is excess clearance,
Ce, which is adjusted out during subsequent
braking. During the return stroke, return spring ▼
(38) ensures that cross bar (41) travels back.

67 52
C - During the first part of the return stroke,
transmitted force decreases. The spline joint
between hub (67) and sychronisation shaft (52)
changes flank which equates to the design clearance.

38 41
8 Description of operation

E - Corresponds to forward stroke movement 63

through E. Adjuster unit housing (62), adjustment 62
spring (63) and companion flange (68) are rotated 68
in relation to hub (67), which itself remains 66
stationary. Movement of companion flange (68) and 67
hub (67) is allowed by of friction spring (66). ▼

52

Ce - During the last part of the return stroke

(corresponding to the movement of the forward 54
stroke through Ce), rotational movement in adjuster 63
unit (54) continues as described under E until 62
mechanism (4) reaches its rest position. 68
66
The brake is now back in its rest position. ▼
67

52
Brake torque

54

Adjustment
phase
(Ce)

Free stroke Elasticity

(C) (E)
 Description of operation 9

Recycling
When replacing the disc brake or parts thereof, the components removed must be recycled/destroyed in
compliance with applicable environmental legislation, regulations and provisions.

Safety instructions
• Always follow the vehicle manufacturer’s safety instructions when working on the vehicle.
• Follow the vehicle manufacturer’s instructions for jobs not described in this manual.
• Comply with local safety regulations.
• Work must be carried out by trained personnel.
• Near-accidents are warning signs that must be respected to prevent injury!
• Brake pad wear and brake pad machining produce very fine dust/fibres which can cause lung damage.
Wear respiratory protection in order to avoid inhaling brake dust particles which can be hazardous to
your health!
• Use the specified type of dust washing equipment or vacuum cleaner to clean surfaces. Do not use
compressed air.
• Ensure that there is sufficient ventilation at the workplace.
• Always use approved equipment such as extractors, protective clothing/masks/gloves/shoes/goggles.
• Sudden release of tensioned springs, e.g. the spring brake part of the brake chamber or the disc brake
return spring, may cause injury.
• Use recommended tools only.
• Release pressure from lines and components before opening them.
• Chock at least one of the vehicle’s axles to prevent involuntary movement of the vehicle.
• After carrying out work, always finish by checking operation/test driving to ensure that the brakes
are working correctly.

Means that special attention is required!

Cleaning
For the disc brake’s function it is important to keep it clean so its normal movements are not limited by
mud, ice, snow, objects etc.

To avoid causing damage or displacing hoses, seals and other components

when cleaning/washing/removing snow/ice it is important to take care
with the use of chemicals, high pressure cleaner and cleaning tools
(ex. glazing knife, brush etc.)!

The result of damage may be immediate loss of the brake function or ingress of moisture / dirt and in turn
function irregularities.
10 Tools

Tools

Special tools for Haldex disc brake.

For number references in ( ) in the text which do not appear in this section, refer to the exploded view
(p. 91-92)

Contents of tool kit Haldex P/N 81918.

Part no.

P/N 81920 Slide hammer (puller) for pads (5).

P/N 81921 Expansion drift for slide bearing (14).

P/N 81922 Fitting tool for slide pin seal (12) in calliper (2).

P/N 87833 Fitting tool for adjustment screw bellows (32) in cover (33).

P/N 81927 Protective cover for brake chamber opening in calliper (2).

P/N 81928 Support plug (used in conjunction with 87833), and fitting tool for adjustment shaft
radial seal (55). (Two part tool).

P/N 81919 Toolbox.

P/N 81933 Torx E18 socket for slide pin bolts (10).

Spare parts
P/N 87857 Spare parts kit for P/N 81920

P/N = Part Number

 Tools 11

Tool kit P/N 81918

81919
87857

81920 81921

81922 87833 81933

81927 81928
12 Maintenance

Service / maintenance
For number references in ( ) in the text which do not appear in this section, refer to the exploded view
(p. 91-92)

Visual inspection: Page

• Checking pad wear (without removing wheels) 13

• Checking protection plugs (15) 13

Maintenance intervals
Check the following items every 12 months.

• Brake linings (with pads removed) (5) 14

• Brake discs 15

• Calliper sliding function 16

• Slide pin play (13) 16

• Slide pin bellows (12) 17

• Adjustment screw bellows (32) 17

• Function testing 18

IMPORTANT!

Read the safety instructions carefully. See the section entitled ’Safety’. The vehicle
manufacturer’s instructions should also be followed.

Clean the disc brakes, removing any dirt and dust. Use dust removal equipment or
a vacuum cleaner but do not use compressed air - inhaling dust particles may be
harmlul to your health! See ”Cleaning” for instructions.

If the disc brake has a parking brake function,

ensure that it is fully disengaged and
mechanically caged in accordance with the
vehicle manufacturer’s instructions.

See the vehicle manufacturer’s instructions for

more information.
 Maintenance 13

Checking pad wear, visual

An indication of wear can be obtained, without having to remove the wheels, by conducting a visual check
as described below.

1. Disc brake with bellows (12) and protection cap (9) for internal slide pins (13):

The position of the protection cap (9) in relation to the calliper (2). See fig. 1 below.

2. Disc brake with protective cup (71) for internal slide pins (13):

Position for brake calliper (2) indicator (A) in relation to the (outer) conical section of the indicator arrow.

See fig. 2 below.

2 12 9
71 A
2

Fig. 1 Fig. 2

NB

The indicator only shows the level of wear suffered by the outer brake pad!

For a more in-depth analysis of pad wear, see Service/Maintenance, ’Checking pad
wear’ (with brake pads removed (5)).

Checking plugs
Plugs (15) protect mechanism (4) from water and
dirt. It is therefore important that these are fitted
correctly. Plugs (15) must be fully pressed into
position. (See diagram.) If remedial measures are
required, see ”Initial settings” (in this section).

15
14 Maintenance

The checks outlined in subsequent sections should be conducted with brake pads (5) removed. See section
entitled ’Replacing brake pads’ for instructions regarding the removal of brake pads.

Checking pads
Measure the distance from backplate (A) to wear
surface (B) of pad (5).

Minimum permitted lining thickness (friction ma-

terial) 2mm. (New pads, lining thickness = 22mm.)
Replace pads if they are worn out or if they are
expected to be before the next service.

Replace the pads!

22 mm
▼
Pad thickness

2 mm

2 mm
0 mm 0 mm
Service Service Service Service

Also check that pads (5) are evenly worn, max. 1

mm uneven wear (measured at four points). In the
event of uneven wear, check the sliding function of
calliper (2) on slide pins (13). See ’Checking slide
function’ (in this section).

Also check that there is no dirt between thrust plates

(28) and pads (5), and that both thrust plates (28)
are adjusted during function testing. See ’Function
testing’ in this section for procedure.

NB

Driving with light braking may result in increased

wear on inner brake pad.
 Maintenance 15

Checking brake disc

Measure the thickness of brake disc (A) using slide B B
calliper. If brake disc (A) has a wear ridge, the
measurement can be performed using two spacers
(B) (e.g. 5mm thick flat washers). Reduce the
measured dimension by the total thickness of the
two spacers (B). Min. thickness of brake disc 37 mm.
In a ventilated disc, max. wear is 4 mm per side.

A
Check/adjust wheel bearing play in accordance with
the vehicle manufacturer’s instructions.

Measure the lateral runout of brake disc (A) by

attaching a magnetic stand complete with a dial
gauge on carrier (3). Point the tip of the dial gauge
towards the side of brake disc (A) and rotate the
brake disc > one turn. Max lateral runout 0.5 mm.

NB Do not include wheel bearing play in the

measurement!

Cracks in the brake disc Crack length

Check the brake disc (A) for cracks and wear tracks. < 75% of brake disc width

If action is required, see the vehicle manufacturer’s Accepted cracking

instructions for dressing / replacing the brake disc.

Crack length

> 75% of brake disc width

Unaccepted cracking
16 Maintenance

Slide function
Check the sliding motion of the calliper (2) on slide
pins (13). The calliper (2) must be free to slide on
the slide pins (13), max. slide resistance 100 N. If
slide resistance is higher, check that the movement
is not hindered by external dirt, foregin objects etc.
If remedial measures are required, see section
entitled ’Replacing slide pins, slide bearings and Max 100N
seals’.

13

Checking play in the slide pins

Measure the play in the outer slide pins (13) by
attaching a magnetic stand complete with a dial
gauge on carrier (3), with the tip of the dial gauge
on point (A) as illustrated. Lift and lower the calliper
(2) outside the brake disc and read off the dial gauge. B
Repeat the procedure inside the brake disc for the
inner slide pins (13) and measure at point (B). The 13
method for obtaining a play, measurement must be
adapted to the ’clock position’ of the disc brake. A
The example here shows the disc brake in the ’12.00’ 13
position. Max. play 1.0 mm. If remedial measures 3
are required, see the section entitled ’Replacing slide
pins. slide bearings and seals’.
 Maintenance 17

Checking slide pin bellows

Check protection caps (9) and bellows (12). (2 per
slide pin).

If there are signs of cracks or other damage,

bellows (12) and protection caps (9) must be
replaced!

If remedial measures are required, see the section

entitled ’Replacing slide pins. slide bearings and
bellows’.

Disc brakes with cups (71) which act as protection 9 12

for the the outer part of slide pins (13) = 6 bellows
(12) and 2 cups (71). Inspect the cups in respect of
leak-tightness and damage. Replace cups (71) if
required.

71

Checking adjustment screw

bellows
Using an 8mm ring spanner, rotate adjustment shaft 32
(55) until protection springs (30) become fully
visible. However, thrust plates (28) must be max.
50 mm away from cover (33)!
33
Inspect protection springs (30). Pull protection
30
springs (30) back and inspect bellows (32).
max 50 mm!
If there are signs of cracking or other damage,
the protection springs/bellows must be replaced!

Turn adjustment shaft (55) back fully. Do not

tighten, as this may damage mechanism (4)!

If remedial measures are required, see the section 28

entitled ’Replacing adjustment screw bellows’.

The checks outlined in this section should be

conducted with brake pads (5) removed. See section
entitled ’Replacing brake pads’ for brake pad fitting
instructions, and the section entitled ’Initial setting’.
18 Function test

Function test
For number references in ( ) in the text which do not appear in this section, refer to the exploded view
(p. 91-92)

• Lift up and support the axle in accordance with the vehicle manuafacturer’s instructions.

IMPORTANT!

Read the safety instructions carefully. See the section entitled ’Safety’.

The vehicle manufacturer’s instructions should also be followed.

• Check that the wheel can be turned freely.

• Remove protective plug (15). Release the brake by turning the adjustment shaft (55) using an 8mm
ring spanner (3/4 turn).

Release Release
clockwise anticlockwise

Note that the brake can be released in both

clockwise and anticlockwise directions depending
on which of the two recesses the release is carried
out in. With the disc brake positioned with the brake
chamber at the top and viewed from the side on
55
which the hexagon of the adjustment shaft (55) is
accessible, turn the adjustment shaft located in the
right-hand recess anticlockwise or, if it is located in
the left-hand recess, turn the shaft clockwise to re-
lease the brake.

Leave the ring spanner in position on the adjustment

shaft (55). Actuate the brakes five times. The spanner
must move on each actuation, showing that the
automatic adjustment is working.
x5
NB The ring spanner must be allowed to move
unhindered!

If the ring spanner moves to and fro or does not

move at all, the mechanism is faulty and must be
replaced.

See section entitled ’Replacing the mechanism’.

Carry out initial setting.

 Initial setting 19

Initial setting
Check that brake disc (A) can be turned freely.

Using an 8mm ring spanner, turn adjustment shaft

(55) until both pads (5) touch brake disc (A).

Then loosen 1/4 turn to obtain a basic clearance

between pads (5) and brake disc (A). Check that
brake disc can be turned freely. Remove the ring
spanner.
A

IMPORTANT!

Never use an impact wrench or

other similar device as they may
damage the mechanism!

55
A
Check plugs (15) and radial seals (69) for wear and
damage. Clean/replace if required.
15
See ’Replacement instructions’ at the end of this
section.

Lubricate plug (15) inside and out and in adjustment

shaft (55) recesses in calliper (2) with grease 55
P/N 89652.

15

15

Fit protective plugs (15) for adjustment shaft (55).

Check that both plugs (15) are pressed firmly into
position. (See illustration)

15
20 Initial setting

NB Protective plugs (15) protect mechanism (4) from water and dirt. It is therefore
important that these are fitted correctly!

In order to obtain the correct clearance between

brake disc (A) and pads (5), mechanism (4) will
itself make the final fine adjustments during a
number of braking operations.

Drift

69

Radial seal (69) replacement instruction.

Puncture radial seal (69) using a hammer and drift,

as shown in the illustration. Insert a self tapping
screw into seal (69). Continue to screw until the seal Self tapping screw
comes away (the screw acts as a puller). Clean and
lubricate the area behind seal (69) with grease
P/N 89652 and tap in a new seal (69) using the in-
ner part of special tool P/N 81928. Continue by
69
lubricating plug (15) as outlined above.

P/N81928

69

Fit wheels (if removed), lower the axle, remove the

support and the wheel chocks in accordance with
the vehicle manufacturer’s instructions.
 Lubrication 21

Lubrication

IMPORTANT!
Read the safety instructions carefully. See the section entitled ’Safety’.
The vehicle manufacturer’s instructions should also be followed.

General
Use specified lubricant only!

With the lifetime of the brake in mind, it is important

only to use specified lubricants for the lubrication
point concerned. Apply the correct amount of
lubricant - do not apply excessive quantities to avoid
lubricant being dispersed or causing damage during
the natural movements of the brake (on pad friction
surfaces, on the brake disc, in bellows etc.).

Mechanism
Mechanism (4) is lubricated in the factory and, as
such, does not normally require further lubrication.
If additional lubrication is required, e.g. when remo-
ving/fitting the mechanism, see the section entitled
’Specifications’ for more information about the type
of lubricant that should be used.

Slide pins and bushings

Lubricate sparingly during assembly.

See the section entitled ’Specifications’ for more

information about the type of lubricant that should
be used.
22 Replacing brake pads

Repairs
Replacing pads
For number references shown within ( ) that do not appear in this section, see the exploded view
(p. 91-92)

• Always replace pads on both sides of the axle at the same time.

• Do not replace with pads of a lining quality that is different to that intended for the installation! (see
current spare parts catalogue)

IMPORTANT!

Follow the safety instructions. See the section entitled ’Safety’.

The vehicle manufacturer’s instructions should also be followed.

• Follow the vehicle manufacturer’s instructions to chock the wheels on an axle which is not to be
raised.

• Lift the axle, support, and remove the wheels in accordance with the vehicle manufacturer’s instructions.

Clean the brakes, removing any dirt and dust. Use dust removal equipment or a
vacuum cleaner but do not use compressed air - inhaling dust particles may be
hazardous to your health! See ”Cleaning” for instructions.

If the disc brake has a parking function,

ensure that it is fully disengaged and mechanically
caged in its disengaged position.

See the vehicle manufacturer’s instructions for

more information.
 Replacing brake pads 23

Removing pads
Remove plug (15) for adjustment shaft (55).

Using an 8mm ring spanner, undo the brake

adjustment by turning adjustment shaft (55) until
Release Release
the adjustment device is fully deadjusted. Do not clockwise anticlockwise
use excessive force, as you may damage
mechanism (4)!

IMPORTANT!

Never use a impact wrench or

similar device as this may
damage mechanism (4)!
55

Note that the brake can be released in both

clockwise and anticlockwise directions depending
in which of the two recesses the release is carried
out. With the disc brake positioned with the brake
chamber at the top and viewed from the side on
which the hexagon of adjustment shafts (55) are
accessible, turn adjustment (55) shaft located in the
right-hand recess anticlockwise and/or in the left-
hand recess clockwise to release the brake.
7

8
Remove bolt (8) and pad retainer (7).

6
6
24 Replacing brake pads

6
Remove pad springs (6). Remove pads (5).
5

If needed, use special tool P/N81920 to remove pads P/N81920

(5). Clean the pad (5) contact surfaces on thrust 5
plates (28), in calliper (2) and on carrier (3) with a
wire brush. Do not grind!

Slide function
Check the sliding motion of calliper (2) on slide pins
(13). The calliper (2) must be free to slide on slide
pins (13), max. slide resistance 100 N. If slide
resistance is higher, check that the movement is not
hindered by external dirt, foreign objects etc. If
remedial measures are required, see section entitled
’Replacing slide pins, slide bearings and seals’.

Max 100N

13
 Replacing brake pads 25

Checking play in the slide pins

Measure the play in the outer slide pins (13) by
attaching a magnetic stand complete with a dial
gauge on carrier (3), with the tip of the dial gauge
on point (A) as illustrated. Lift and lower the calliper
(2) outside the brake disc and read off the dial gauge.
Repeat the procedure inside the brake disc for the
inner slide pins (13) and measure at point (B). The
B
method for obtaining a play measurement must be
adapted to the ’clock position’ of the disc brake. 13
The example here shows the disc brake in the ’12.00’
position. Max. play 1.0 mm. If remedial measures A
are required, see the section entitled ’Replacing slide 13
pins slide bearings and seals’. 3

Checking slide pin bellows

Check protection caps (9) and bellows (12). (2 per
slide pin).

If there are signs of cracks or other damage,

bellows (12) and protection caps (9) must be
replaced!

If remedial measures are required, see the section

entitled ’Replacing slide pins. slide bearings and
bellows’.
9 12
Disc brakes with cups (71) which act as protection
for the the outer part of slide pins (13) = 6 bellows
(12) and 2 cups (71). Inspect the cups in respect of
leaktightness and damage. Replace cups (71) if
required.

71
26 Replacing brake pads

Checking adjustment screw

bellows 32

Using an 8mm ring spanner, rotate adjustment shaft

(55) until the protection springs (30) become fully
visible. However, thrust plates (28) must be max.
33
50 mm away from cover (33)!
30
Inspect protection springs (30). Pull protection max 50 mm!
springs (30) back and inspect bellows (32).

If there are signs of cracking or other damage,

the protection springs/bellows must be replaced!

Turn adjustment shaft (55) back fully. Do not

tighten, as this may damage mechanism (4)! 28

If remedial measures are required, see the section

entitled ’Replacing adjustment screw bellows’.

B B

Checking brake disc

Measure the thickness of brake disc (A) using slide
calliper. If brake disc (A) has a wear ridge, the
measurement can be performed using two spacers
(B) (e.g. 5mm thick flat washers). Reduce the
measured dimension by the total thickness of the
two spacers (B). Min. thickness of brake disc 37 mm.
In a ventilated disc, max. wear is 4 mm per side.

A
Check/adjust wheel bearing play in accordance with
the vehicle manufacturer’s instructions.

Measure the lateral runout of brake disc (A) by

attaching a magnetic stand complete with a dial
gauge on carrier (3). Point the tip of the dial gauge
towards the side of the brake disc (A) and rotate
the brake disc > one turn. Max lateral runout 0.5
mm.

3
NB Do not include wheel bearing play in the
measurement!
A
 Replacing brake pads 27

Cracks in the brake disc Crack length

Check the brake disc (A) for cracks and wear tracks. < 75% of brake disc width

If action is required, see the vehicle manufacturer’s Accepted cracking

instructions for dressing / replacing the brake disc.

Crack length

> 75% of brake disc width

Unaccepted cracking

Fitting pads 6
7
Using an 8mm ring spanner, ensure that adjustment
(55) is fully deadjusted. NB Do not use excessive
force, as you may damage mechanism (4)! Check
that pad (5) contact surfaces in the disc brake are
clean.

6
5

M10 45±5Nm 8
Fit pads (5), pad springs (6), pad retainer (7) and M8 20 ±3 Nm
secure with bolt (8). Tightening torques M10
45±5Nm and M8 20 ±3 Nm.
28 Replacing brake pads

Initial setting
Check that brake disc (A) can be turned freely.

Using an 8mm ring spanner, turn adjustment shaft

(55) until both pads (5) touch brake disc (A).

Then loosen 1/4 turn to obtain a basic clearance

between pads (5) and brake disc (A). Check that
brake disc (A) can be turned freely. Remove the ring
spanner.
A

IMPORTANT!

Never use an impact wrench or

other similar device as they may
damage the mechanism!

55
A
Check plugs (15) and radial seals (69) for wear and
damage. Clean/replace if required.
15
See ’Replacement instructions’ at the end of this
section.

Lubricate plug (15) inside and out and in adjustment

55
shaft (55) recesses in calliper (2) with grease
P/N 89652.

15

15

15
 Replacing brake pads 29

NB Protective plugs (15) protect mechanism (4) from water and dirt. It is therefore
important that these are fitted correctly!

In order to obtain the correct clearance between

brake disc (A) and pads (5), mechanism (4) will
itself make the final fine adjustments during a
number of braking operations.

Drift

69

Radial seal (69) replacement instruction.

Puncture radial seal (69) using a hammer and drift,
as shown in the illustration. Insert a self tapping
screw into seal (69). Continue to screw until the seal
comes away (the screw acts as a puller). Clean and
lubricate the area behind seal (69) with grease Self tapping screw
P/N 89652 and tap in a new seal (69) using the in-
ner part of special tool P/N 81928. Continue by
lubricating plug (15) as outlined above.
69

P/N81928

69
30 Replacing brake pads

Disc brake with spring brake chamber

Make sure that there is sufficient air in the system

(min. 6 bar).

Apply air pressure to the parking brake (min. 6 bar).

Uncage the parking brake spring.

See the vehicle manufacturer’s instructions for more information.

With the service brake engaged and, where

appropriate, with the parking brake released, check
the brake chambers, hoses and connections in
respect of leak-tightness and damage.

Fit the wheels as per the vehicle manufacturer’s

instructions.

NB

Check that the contact surface of the rim and hub

are clean and free from distortion. Follow the
vehicle manufacturer’s instructions for fitting and
tightening torques!

Check that the brake hoses do not foul during full wheel articulation.

Check the wheel so it turns freely with the

parking brake released.

Remove the axle support and the wheel chocks

and lower the axle in accordance with the vehicle
manufacturer’s instructions.
 Replacing disc brake 31

Replacing disc brake

For number references shown within ( ) that do not appear in this section, see the exploded view
(p. 91-92)

IMPORTANT!

Follow the safety instructions. See the section entitled ’Safety’.

The vehicle manufacturer’s instructions should also be followed.

• Follow the vehicle manufacturer’s instructions to chock the wheels on an axle which is not to be
raised.

• Lift the axle, support, and remove the wheels in accordance with the vehicle manufacturer’s instructions.

Clean the brakes, removing any dirt and dust. Use dust removal equipment or a
vacuum cleaner but do not use compressed air - inhaling dust particles may be
hazardous to your health! See ”Cleaning” for instructions.

If the disc brake has a parking function,

ensure that it is fully disengaged and mechanically
caged in its disengaged position.

See the vehicle manufacturer’s instructions for more information.

32 Replacing disc brake

Removing pads
Remove plug (15) for adjustment shaft (55).
Release Release
Using an 8mm ring spanner, undo the brake clockwise anticlockwise
adjustment by turning adjustment shaft (55) until
the adjustment device is fully deadjusted. Do not
use excessive force, as you may damage
mechanism (4)!

IMPORTANT!

Never use a impact wrench or 55

similar device as this may
damage the mechanism!

Note that the brake can be released in both

clockwise and anticlockwise directions depending
in which of the two recesses the release is carried
out. With the disc brake positioned with the brake
chamber at the top and viewed from the side on
which the hexagon of adjustment shafts (55) are
accessible, turn adjustment (55) shaft located in the
right-hand recess anticlockwise and/or in the left-
hand recess clockwise to release the brake.

8
Remove the bolt (8) and pad retainer (7).

6
 Replacing disc brake 33

Remove pad springs(6). Remove the pads (5). 6

If needed, use special tool P/N81920 to remove pads P/N81920

(5). 5

27
Removing brake chamber
Spring brake chamber - ensure that the spring is
caged. See the vehicle manufacturer’s instructions
for more information.
▼ A
Remove the two nuts (27) holding brake chamber
(25/26).

25/26
Remove brake chamber (25) / spring brake chamber
(26) and support it so that hoses and connections
(A) are not damaged.
34 Replacing disc brake

Checking brake disc

Measure the thickness of brake disc (A) using slide B B
calliper. If brake disc (A) has a wear ridge, the
measurement can be performed using two spacers
(B) (e.g. 5mm thick flat washers). Reduce the
measured dimension by the total thickness of the
two spacers (B). Min. thickness of brake disc 37 mm.
In a ventilated disc, max. wear is 4 mm per side.

A
Check/adjust wheel bearing play in accordance with
the vehicle manufacturer’s instructions.

Measure the lateral runout of brake disc (A) by

attaching a magnetic stand complete with a dial
gauge on carrier (3). Point the tip of the dial gauge
towards the side of brake disc (A) and rotate the
brake disc > one turn. Max lateral runout 0.5 mm.

NB Do not include wheel bearing play in the

measurement!

Cracks in the brake disc 3

Check the brake disc (A) for cracks and wear tracks. Crack length

If action is required, see the vehicle manufacturer’s < 75% of brake disc width
instructions for dressing / replacing the brake disc.
Accepted cracking

Crack length

> 75% of brake disc width

Unaccepted cracking
 Replacing disc brake 35

Removing disc brake

22 22
Remove two of the disc brake’s three retaining bolts
(22) on each side.

Fit pad retainer (7) and secure with bolt (8). Connect
a lifting strap and a suitable lifting device.

Remove the two remaining retaining bolts (22) and

lift out the disc brake.

8
Fitting disc brake
Check that the surfaces for fitting to the axle, brake
chamber (25/26) and pads (5) are clean.

Fit pad retainer (7) and secure with bolt (8). Connect
a lifting strap and a suitable lifting device.

Lift the disc brake into position.

Follow the vehicle/axle manufacturers

recommendations for fitting/tightening bolts (22)
or follow the method as described below:

Lubricate bolts (22) in with anti-seize compound

P/N81934.

Always use new bolts (22) for sizes marked * in

the table below.

22
100 ±5Nm +
angle tightening
Fit one bolt (22) on each side of the calliper (2).

Remove the lifting strap, bolt (8) and pad retainer

(7).

Fit the other bolts (22) and tighten all bolts to 100±5
Nm and then angle tighten for the relevant bolt as
set out in the table below. Use a standard protractor.
36 Replacing disc brake

Angle tightening table M16* M18 M20

Pitch
1.0 mm +70° +70° +80°
1.5 mm +50° +50° +55°
2.0 mm +35° +35° +40°
2.5 mm - +30° +35°

Example: Bolt M 16 x 1.5 * = The bolt must not be

Tighten to 100±5 Nm + re-used
50°
Standard
protractor for
angle tightening

Check the sliding motion of calliper (2) on the slide

pins. Calliper (2) must slide freely on slide pins (13),
max. slide resistance 100N.

Max 100N

13

Fitting brake chamber A

Check the internal bellows (A) in brake chambers 25/26

(25/26) for cracks and damage and that the external
seal flange (B) towards the calliper is intact, ▼
B
particularly if water/dirt has managed to get into
the mechanism area.

If remedial measures are required, see the vehicle

manufacturer’s instructions.

Remove the delivery seal from the brake calliper

(2) brake chamber flange.
 Replacing disc brake 37

Check that there is grease in the ball cup in lever

(44). Top up with grease P/N 89652 if required.

Check that the brake chamber (25/26) mounting

flange is clean. P/N89652

27

Fit brake chamber (25/26) using nuts (27). Tight-

ening torque 180±20 Nm. 180 ±20 Nm

5 5 6

7
Fitting pads
Replace pads (5) if they are worn out or if they are
expected to be so by the time of the next service.
Do not replace with pads of a different quality than 6
intended for the installation. 3
Min. thickness of friction material 2 mm.

If pads (5) are to be re-used, clean their thrust plate

(28) contact surfaces and carrier (3) with a wire
brush. Do not grind!
M10 45±5Nm
Using an 8mm ring spanner, ensure that adjustment M8 20±3Nm
8
shaft (55) is fully deadjusted. NB Do not use
excessive force, as you may damage mechanism
(4)!

Check that pad (5) contact surfaces in the disc brake

are clean. Fit pads (5), pad springs (6), pad retainer
(7) and secure with bolt (8). Tightening torques M10
45±5Nm and M8 20 ±3 Nm.
38 Replacing disc brake

Initial setting
Check that brake disc (A) can be turned freely.

Using an 8mm ring spanner, turn adjustment shaft

(55) until both pads (5) touch brake disc (A).

Then loosen 1/4 turn to obtain a basic clearance

between pads (5) and brake disc (A). Check that
brake disc (A) can be turned freely. Remove the ring
spanner.
A

IMPORTANT!

Never use an impact wrench or

other similar device as they may
damage the mechanism!

55
A
Lubricate plug (15) inside and out and in adjustment
shaft (55) recesses in calliper (2) with grease
15
P/N 89652.

55

15

15

Fit protective plugs (15) for adjustment shaft (55).

Check that both plugs (15) are pressed firmly into
position. (See illustration)

15
 Replacing disc brake 39

NB Protective plugs (15) protect mechanism (4) from water and dirt. It is therefore
important that these are fitted correctly!

In order to obtain the correct clearance between

brake disc (A) and pads (5), mechanism (4) will
itself make the final fine adjustments during a
number of braking operations.
40 Replacing disc brake

Disc brake with spring brake chamber

Make sure that there is sufficient air in the system

(min. 6 bar).

Apply air pressure to the parking brake (min. 6 bar).

Uncage the parking brake spring.

See the vehicle manufacturer’s instructions for more information.

With the service brake engaged and, where

appropriate, with the parking brake released, check
the brake chambers, hoses and connections in
respect of leak-tightness and damage.

Fit the wheels as per the vehicle manufacturer’s

instructions.

NB

Check that the contact surface of the rim and hub

are clean and free from distortion. Follow the
vehicle manufacturer’s instructions for fitting and
tightening torques!

Check that the brake hoses do not foul during full wheel articulation.

Check the wheel so it turns freely with the

parking brake released.

Remove the axle support and the wheel chocks

and lower the axle in accordance with the vehicle
manufacturer’s instructions.
 Replacing bellows for adjustment screws 41

Replacing bellows for adjustment screws

For number references shown within ( ) that do not appear in this section, see the exploded view
(p. 91-92)

IMPORTANT!

Follow the safety instructions. See the section entitled ’Safety’.

The vehicle manufacturer’s instructions should also be followed.

• Follow the vehicle manufacturer’s instructions to chock the wheels on an axle which is not to be
raised.

• Lift the axle, support, and remove the wheels in accordance with the vehicle manufacturer’s instructions.

Clean the brakes, removing any dirt and dust. Use dust removal equipment or a
vacuum cleaner but do not use compressed air - inhaling dust particles may be
hazardous to your health! See ”Cleaning” for instructions.

If the disc brake has a parking function,

ensure that it is fully disengaged and mechanically
caged in its disengaged position.

See the vehicle manufacturer’s instructions for more information.

42 Replacing bellows for adjustment screws

Removing pads
Remove plug (15) for adjustment shaft (55).

Using an 8mm ring spanner, undo the brake

adjustment by turning adjustment shaft (55) until Release Release
the adjustment device is fully deadjusted. Do not clockwise anticlockwise
use excessive force, as you may damage
mechanism (4)!

IMPORTANT!

Never use a impact wrench or

similar device as this may
damage mechanism (4)!
55

Note that the brake can be released in both

clockwise and anticlockwise directions depending
in which of the two recesses the release is carried
out. With the disc brake positioned with the brake
chamber at the top and viewed from the side on
which the hexagon of adjustment shafts (55) are
accessible. Turn adjustment (55) shaft located in the
right-hand recess anticlockwise and/or in the left-
hand recess clockwise to release the brake.
7

8
Remove bolt (8) and pad retainer (7).

6
6
 Replacing bellows for adjustment screws 43

6
Remove pad springs (6). Remove the pads (5).
5

If needed, use special tool P/N81920 to remove pads P/N81920

(5). Clean the pad (5) contact surfaces on thrust 5
plates (28), in calliper (2) and on carrier (3) with a
wire brush. Do not grind!

3
44 Replacing bellows for adjustment screws

Removing bellows 32
Using an 8mm ring spanner, turn adjustment shaft
35/36 28
(55) so that thrust plates (28) are 35-40mm out from
their fully retracted position. Pull back protection
spring (30) and carefully remove bellows (32) from
thrust plate (28) with a screwdriver to access the
joint between thrust plate (28) and adjustment screw
(35/36). Detach thrust plate (28) from adjustment
screw (35/36) using a screwdriver. Do not damage
the contact surfaces!

Do not prize out thrust plate (28)

against cover (33) (with a
screwdriver or similar tool )- 33
28
needle bearings (43/48) may be
displaced and be damaged!

Remove protection spring (30). Rotate adjustment

shaft (55) until adjustment screws (35/36) are fully
retracted.

NB Do not use excessive force, as you may

damage mechanism (4)!

Remove bellows (32) from cover (33) by using a

lever
32 33

NB Do not damage the

adjustment screws and/or
bellows mounting surfaces!

Cleaning
Clean the cover (33), adjustment screws (35/36) and
thrust plate (28).

Ensure that impurities do not

enter the opening for the
adjustment screws!
 Replacing bellows for adjustment screws 45

Inspection. 35/36

Check that the fitting surfaces for bellows (32) in

cover (33) and on the thrust plates (28) are free from
damage. Check that thrust plate clip (29) is intact. 33
The clip must hold thrust plate (28) in adjustment
screws (35/36). Replace or adjust clip (29) if
35/36
necessary. Also check the part of the mechanism (4)
visible beyond adjustment screws (35/36), looking
for signs of corrosion, damage and condensation. If
action is required, mechanism (4) must be replaced.

See section entitled ’Replacing the mechanism’.

Fitting bellows
Position thrust plate (28) in special tool P/N87833.
Thrust plate (28) should run freely into the tool - if
not, clean the thrust plate edge. Check that the clip
(29) is sitting in its groove. Press and twist the
protection spring (30) and fit it into position in spe-
cial tool P/N87833 with the smallest diameter 28
towards thrust plate (28). Press bellows (32) into
position on thrust plate (28) using thumb pressure.
32 P/N87833
Using an 8mm spanner on adjustment shaft (55),
check that adjustment screws (35/36) are fully 29
28 30
retracted. Do not use excessive force, as you may
damage mechanism (4)

Fit the bellows unit (28/29/30/32), including spe-

cial tool P/N87833, in position in the cover (33).
P/N87833 P/N87833
Use a G-clamp in conjunction with special tool 28 30
P/N87833 to press the bellows unit into position in 32
the cover (33). Position the inner part of special tool
P/N81928 as support in the recess for adjustment
shaft (55). 29

Remove the G-clamp, special tool P/N87833 and

P/N81928.
P/N81928
Check that the bellows (32) are pressed fully into
position. Check that protection spring (30) is
correctly fitted. Repeat for fitting the other bellows
units.

Use an 8mm spanner on adjustment shaft (55) to

extend adjustment screws (35/36) sufficiently to
ensure that thrust plates (28) are fully seated in
adjustment screws (35/36). Then turn adjustment
shaft(55) until adjustment screws (35/36) are fully
retracted. NB Do not use excessive force, as you
may damage mechanism (4)
46 Replacing bellows for adjustment screws

Fitting pads
Replace pads (5) if they are worn out or if they are
5 5 6
expected to be so by the time of the next service.
Do not replace with pads of a different quality than 7
intended for the installation.

Min. thickness of friction material 2 mm.

If pads (5) are to be re-used, clean their thrust plate 6

(28) contact surfaces and carrier (3) with a wire
3
brush. Do not grind!

Using an 8mm ring spanner, ensure that adjustment

shaft (55) is fully deadjusted. NB Do not use
excessive force, as you may damage mechanism
(4)!
M10 45±5Nm
Check that the pad (5) contact surfaces in the disc M8 20±3Nm
8
brake are clean. Fit pads (5), pad springs (6), pad
retainer (7) and secure with bolt (8). Tightening
torques M10 45±5Nm and M8 20 ±3 Nm.
 Replacing bellows for adjustment screws 47

Initial setting
Check that brake disc (A) can be turned freely.

Using an 8mm ring spanner, turn adjustment shaft

(55) until both pads (5) touch brake disc (A).

Then loosen 1/4 turn to obtain a basic clearance

between pads (5) and brake disc (A). Check that
brake disc (A) can be turned freely. Remove the ring
spanner.
A

IMPORTANT!

Never use an impact wrench or

other similar device as they may
damage the mechanism!

55
A
Check plugs (15) and radial seals (69) for wear and
damage. Clean/replace if required.
15
See ’Replacement instructions’ at the end of this
section.

Lubricate plug (15) inside and out and in adjustment

55
shaft (55) recesses in calliper (2) with grease
P/N 89652.

15

15

Fit protective plugs (15) for adjustment shaft (55).

Check that both plugs (15) are pressed firmly into
position. (See illustration)

15
48 Replacing bellows for adjustment screws

NB Protective plugs (15) protect mechanism (4) from water and dirt. It is therefore
important that these are fitted correctly!

In order to obtain the correct clearance between

brake disc (A) and pads (5), mechanism (4) will
itself make the final fine adjustments during a
number of braking operations.

Drift

69

Radial seal (69) replacement instruction.

Puncture radial seal (69) using a hammer and drift,

as shown in the illustration. Insert a self tapping
screw into seal (69). Continue to screw until the seal
comes away (the screw acts as a puller). Clean and Self tapping screw
lubricate the area behind seal (69) with grease
P/N 89652 and tap in a new seal (69) using the in-
ner part of special tool P/N 81928. Continue by
lubricating plug (15) as outlined above.
69

P/N81928

69
 Replacing bellows for adjustment screws 49

Disc brake with spring brake chamber

Make sure that there is sufficient air in the system

(min. 6 bar).

Apply air pressure to the parking brake (min. 6 bar).

Uncage the parking brake spring.

See the vehicle manufacturer’s instructions for more information.

With the service brake engaged and, where

appropriate, with the parking brake released, check
the brake chambers, hoses and connections in
respect of leak-tightness and damage.

Fit the wheels as per the vehicle manufacturer’s

instructions.

NB

Check that the contact surface of the rim and hub

are clean and free from distortion. Follow the
vehicle manufacturer’s instructions for fitting and
tightening torques!

Check that the brake hoses do not foul during full wheel articulation.

Check the wheel so it turns freely with the

parking brake released.

Remove the axle support and the wheel chocks

and lower the axle in accordance with the vehicle
manufacturer’s instructions.
50 Replacing slide pins, slide bearings and bellows

Replacing slide pins, slide bearings and

bellows
For number references shown within ( ) that do not appear in this section, see the exploded view
(p. 91-92)

IMPORTANT!

Follow the safety instructions. See the section entitled ’Safety’.

The vehicle manufacturer’s instructions should also be followed.

• Follow the vehicle manufacturer’s instructions to chock the wheels on an axle which is not to be
raised.

• Lift the axle, support, and remove the wheels in accordance with the vehicle manufacturer’s instructions.

Clean the brakes, removing any dirt and dust. Use dust removal equipment or a
vacuum cleaner but do not use compressed air - inhaling dust particles may be
hazardous to your health! See ”Cleaning” for instructions.

If the disc brake has a parking function,

ensure that it is fully disengaged and mechanically
caged in its disengaged position.

See the vehicle manufacturer’s instructions for more information.

 Replacing slide pins, slide bearings and bellows 51

Removing pads
Remove plug (15) for adjustment shaft (55). Release Release
clockwise anticlockwise
Using an 8mm ring spanner, undo the brake
adjustment by turning adjustment shaft (55) until
the adjustment device is fully deadjusted. Do not
use excessive force, as you may damage
mechanism (4)!

IMPORTANT!

Never use a impact wrench or 55

similar device as this may
damage the mechanism!

Note that the brake can be released in both

clockwise and anticlockwise directions depending
in which of the two recesses the release is carried
out. With the disc brake positioned with the brake
chamber at the top and viewed from the side on
which the hexagon of adjustment shafts (55) are
accessible, turn adjustment (55) shaft located in the
right-hand recess anticlockwise and/or in the left-
hand recess clockwise to release the brake.

8
Remove the bolt (8) and pad retainer (7).

6
52 Replacing slide pins, slide bearings and bellows

Remove pad springs(6). Remove the pads (5). 6

If needed, use special tool P/N81920 to remove pads P/N81920

(5). 5

27
Removing brake chamber
Spring brake chamber - ensure that the spring is
caged. See the vehicle manufacturer’s instructions
for more information.
▼ A
Remove the two nuts (27) holding brake chamber
(25/26).

25/26
Remove brake chamber (25) / spring brake chamber
(26) and support it so that hoses and connections
(A) are not damaged.
 Replacing slide pins, slide bearings and bellows 53

Check through the aperture in the brake chamber

attachment flange for moisture / corrosion. If pre-
sent, replace mechanism (4) to avoid early failure.

If action is required see section on ”Replacing

mechanism”. To protect mechanism (4), fit

▼
protection cover P/N81927.
P/N
819
27

Removing disc brake

22 22
Remove two of the disc brake’s three retaining bolts
(22) on each side.

Fit pad retainer (7) and secure with bolt (8). Connect
a lifting strap and a suitable lifting device.

Remove the two remaining retaining bolts (22) and 7

lift out the disc brake.

8
54 Replacing slide pins, slide bearings and bellows

Removing slide pins, slide bearings

and bellows
Position the disc brake in a vice. Use protection jaws

Remove the four protection caps (9), using a

hammer and chisel.

The protection caps (9) must never be re-used.

Disc brake with cups (71): remove two protection

caps (9) and two cups (71).

Remove the four slide pin fixing bolts (10) using

special tool P/N81933 (Torx E18 socket). Press the
slide pins (13) back (enough to remove carrier (3)
from calliper (2)) by rocking carrier (3) to and fro.

71

NB
3
Do not use gripping tools or 2
similar - this will damage the slide
pin sealing surfaces!

9
 Replacing slide pins, slide bearings and bellows 55

If slide pins (13) are seized in carrier (3), cut threads 2

on the inside of slide pins (13) using an M16x2 tap 3
and special tool P/N81920 ( slide hammer without Thread tap
7
yoke) as a puller. M16x2

▼
Remove carrier (3) from calliper (2).

13

P/N81920

NB Only grip on external surfaces! 3

Clean the components, removing

any dirt and dust. Use dust rem-
oval equipment or a vacuum
cleaner, but do not use
compressed air - inhaling dust
particles may be harmful to your
health!

Remove the bellows rings (11). 2

Press the four slide pins (13) out from calliper (2).

Remove 8 bellows (12) by carefully levering them

out. (6 bellows as cups (71) protect the inner slide
pins (13).)

NB Do not damage the mounting surfaces!

12
56 Replacing slide pins, slide bearings and bellows

Remove the four slide bearings (14) (which are of

split design) using a small screwdriver. Begin at the 14
split.

NB Do not damage the mounting surfaces! 2

Inspection.
Check that the fitting surfaces for slide bearings (14)
and bellows (12) /cups (71) are not damaged.

13

Fitting slide bearings, slide pins, 14

14
bellows
Slide bearings (14) are supplied as a band.

Shape (4pcs.) slide bearings (14) in 2-steps as shown

in the pictures (the ends of the bearing band must
touch each other) and fit them in position in calliper P/N81921
(2).

Expand the slide bearings (14) by pressing/twisting

14
through special tool P/N81921.

14
P/N81921
 Replacing slide pins, slide bearings and bellows 57

Lubricate slide pins (13) and slide bearings (14) 13 13

sparingly using grease P/N 89652 and press them
into position in slide bearings (14).

Slide pins (13) of an earlier design (asymmetrical): 13

Note the direction of the offset in the slide pins (13)
13
and that the diameter of the end of the slide pin
(13) which fits against the carrier boss (3) is less than
13
that of the end in which the protection cap (9) fits.
( small diameter on the carrier (3) and ’deep’ offset
on the brake chamber side). (See illustration, two
different designs.)

Later slide pins (13) are symmetrical, both ends

fit into the carrier (3). Carriers (3) designed for 13
13
symmetrical slide pins (13) cannot accommodate
slide pins with offsets and vice versa. (See illustra-
tion, different designs.) Refer to current spare parts
catalogue to choose spare parts.

Slide pins (13) must be able to slide easily in slide 2 13

bearings (14) to ensure that that calliper (2) floats
over carrier (3).
58 Replacing slide pins, slide bearings and bellows

2
Fit the bellows (12) in calliper (2) using special tool
P/N81922.

Slide pins protected by cups (71): Cups (71) are fitted

after torx bolt (10) has been tightened.

12
P/N81922
(Consists of three
parts)
2
Press the outer section of bellows (12) into position
in the groove in the slide pin (13) and secure with a
bellows ring (11).

11

13 12
Clean the contact surfaces in carrier (3), calliper (2) 3
and on thrust plates (28). Also clean pads (5) (if these
are to be re-used). Use a wire brush. Do not grind! 2
Sparingly lubricated slide pin (13) and carrier (3)
mounting surfaces with anti-seize compound. P/
N81934.

Press out slide pins (13) so that they are free from
carrier (3) during fitting.

Lift carrier (3) into position in calliper (2) and press

in slide pins (13) so that they fit on carrier (3). Do
not damage bellows (12)!

NB Only grip on external

surfaces! Do not damage the
seals (12)!
 Replacing slide pins, slide bearings and bellows 59

Lubricate the threads on the four slide pin fixing

bolts (10) using anti-seize compound P/N81934 and
P/N81933
screw them into position. Tighten using a torque
(Torx E18 socket)
wrench and special tool P/N81933 (Torx E18
socket) to 220 ±20 Nm.

Check that carrier (3) slides easily in calliper (2).

10
Max. slide resistance with disc brake (1) fitted on
the vehicle axle: 100N. (See maintenance
instructions)

Tap new protection caps (9) into position in the

outer ends of the slide pins (13) using a 17 mm 220 ±20 Nm
socket and an extension. NB The protective cap
must bottom in the slide pin.

Protective caps (9) for asymmetrical slide pins (13)

feature a central hole, whilst protective caps (9) for
symmetrical slide pins (13) do not.

Slide pins (13) protected by cups (71): Carefully

71
tap cups (71) into position in calliper (2).

71

Socket
Extension
60 Replacing slide pins, slide bearings and bellows

Fitting disc brake

Check that the surfaces for fitting to the axle, brake
chamber (25/26) and pads (5) are clean. 7

Fit pad retainer (7) and secure with bolt (8). Connect
a lifting strap and a suitable lifting device.
8
Lift the disc brake into position.

Follow the vehicle/axle manufacturers

recommendations for fitting/tightening bolts (22)
or follow the method as described below:

Lubricate bolts (22) in with anti-seize compound

P/N81934.

Always use new bolts (22) for sizes marked * in

the table below.

Fit one bolt (22) on each side of calliper (2).

Remove the lifting strap, bolt (8) and pad retainer

(7).

Fit the other bolts (22) and tighten all bolts to 100±5
Nm and then angle tighten for the relevant bolt as 22
set out in the table below. Use a standard protractor. 100 ±5Nm +
angle tightening

Angle tightening table M16* M18 M20

Pitch
1.0 mm +70° +70° +80°
1.5 mm +50° +50° +55°
2.0 mm +35° +35° +40°
2.5 mm - +30° +35°

Example: Bolt M 16 x 1.5 * = The bolt must not be

Tighten to 100±5 Nm + re-used
50°

Standard
protractor for
angle tightening
 Replacing slide pins, slide bearings and bellows 61

Check the sliding motion of calliper (2) on the slide

pins. Calliper (2) must slide freely on slide pins (13),
max. slide resistance 100N.

Max 100N

13

25/26

▼
B

Fitting brake chamber

Check the internal bellows (A) in brake chamber
(25/26) for cracks and damage and that the external
seal flange (B) against the calliper is intact.

If remedial measures are required, see the vehicle

manufacturer’s instructions.

Remove special tool (protective cover) P/N81927.

P/N89652

Check that the brake chamber (25/26) contact flange

is free from dirt. Put a knob of grease
P/N 89652 in the ball cup on lever (44).

Fit brake chamber (25/26) using nuts (27). Tight- 27

ening torque 180 ±20 Nm.

180 ±20 Nm
62 Replacing slide pins, slide bearings and bellows

Fitting pads
Replace pads (5) if they are worn out or if they are
5 5 6
expected to be so by the time of the next service.
Do not replace with pads of a different quality than 7
intended for the installation.

Min. thickness of friction material 2 mm.

If pads (5) are to be re-used, clean their thrust plate 6

(28) contact surfaces and carrier (3) with a wire
3
brush. Do not grind!

Using an 8mm ring spanner, ensure that adjustment

shaft (55) is fully deadjusted. NB Do not use
excessive force, as you may damage mechanism
(4)!
M10 45±5Nm
Check that the pad (5) contact surfaces in the disc M8 20±3Nm
8
brake are clean. Fit pads (5), pad springs (6), pad
retainer (7) and secure with bolt (8). Tightening
torques M10 45±5Nm and M8 20 ±3 Nm.
 Replacing slide pins, slide bearings and bellows 63

Initial setting
Check that brake disc (A) can be turned freely.

Using an 8mm ring spanner, turn adjustment shaft

(55) until both pads (5) touch brake disc (A).

Then loosen 1/4 turn to obtain a basic clearance

between pads (5) and brake disc (A). Check that
brake disc (A) can be turned freely. Remove the ring
spanner.
A
IMPORTANT!

Never use an impact wrench or

other similar device as they may
damage the mechanism!

A
Check plugs (15) and radial seals (69) for wear and 55

damage. Clean/replace if required.

See ’Replacement instructions’ at the end of this 15

section.

Lubricate plug (15) inside and out and in adjustment

shaft (55) recesses in calliper (2) with grease 55
P/N 89652.

15

15

Fit protective plugs (15) for adjustment shaft (55).

Check that both plugs (15) are pressed firmly into
position. (See illustration)

15
64 Replacing slide pins, slide bearings and bellows

NB Protective plugs (15) protect mechanism (4) from water and dirt. It is therefore
important that these are fitted correctly!

In order to obtain the correct clearance between

brake disc (A) and pads (5), mechanism (4) will
itself make the final fine adjustments during a
number of braking operations.

Drift

69

Radial seal (69) replacement instruction.

Puncture radial seal (69) using a hammer and drift,

as shown in the illustration. Insert a self tapping
screw into seal (69). Continue to screw until the seal Self tapping screw
comes away (the screw acts as a puller). Clean and
lubricate the area behind seal (69) with grease
P/N 89652 and tap in a new seal (69) using the in-
ner part of special tool P/N 81928. Continue by
lubricating plug (15) as outlined above. 69

P/N81928

69
 Change of slide pins, bushings and seals 65

Disc brake with spring brake chamber

Make sure that there is sufficient air in the system

(min. 6 bar).

Apply air pressure to the parking brake (min. 6 bar).

Uncage the parking brake spring.

See the vehicle manufacturer’s instructions for more information.

With the service brake engaged and, where

appropriate, with the parking brake released, check
the brake chambers, hoses and connections in
respect of leak-tightness and damage.

Fit the wheels as per the vehicle manufacturer’s

instructions.

NB

Check that the contact surface of the rim and hub

are clean and free from distortion. Follow the
vehicle manufacturer’s instructions for fitting and
tightening torques!

Check that the brake hoses do not foul during full wheel articulation.

Check the wheel so it turns freely with the

parking brake released.

Remove the axle support and the wheel chocks

and lower the axle in accordance with the vehicle
manufacturer’s instructions.
66 Change of mechanism

Change of mechanism
For number references shown within ( ) that do not appear in this section, see the exploded view
(p. 91-92)

IMPORTANT!

Follow the safety instructions. See the section entitled ’Safety’.

The vehicle manufacturer’s instructions should also be followed.

• Follow the vehicle manufacturer’s instructions to chock the wheels on an axle which is not to be
raised.

• Lift the axle, support, and remove the wheels in accordance with the vehicle manufacturer’s instructions.

Clean the brakes, removing any dirt and dust. Use dust removal equipment or a
vacuum cleaner but do not use compressed air - inhaling dust particles may be
hazardous to your health! See ”Cleaning” for instructions.

If the disc brake has a parking function,

ensure that it is fully disengaged and mechanically
caged in its disengaged position.

See the vehicle manufacturer’s instructions for more information.

 Change of mechanism 67

Removing pads
Remove plug (15) for adjustment shaft (55).
Release Release
Using an 8mm ring spanner, undo the brake clockwise anticlockwise
adjustment by turning adjustment shaft (55) until
the adjustment device is fully deadjusted. Do not
use excessive force, as you may damage
mechanism (4)!

IMPORTANT!

Never use a impact wrench or 55

similar device as this may
damage the mechanism!

Note that the brake can be released in both

clockwise and anticlockwise directions depending
in which of the two recesses the release is carried
out. With the disc brake positioned with the brake
chamber at the top and viewed from the side on
which the hexagon of adjustment shafts (55) are
accessible, turn adjustment (55) shaft located in the
right-hand recess anticlockwise and/or in the left-
hand recess clockwise to release the brake.

8
Remove bolt (8) and pad retainer (7).

6
68 Change of mechanism

Remove pad springs(6). Remove pads (5). 6

If needed, use special tool P/N81920 to remove pads P/N81920

(5). 5

27
Removing brake chamber
Spring brake chamber - ensure that the spring is
caged. See the vehicle manufacturer’s instructions
for more information.
▼ A
Remove the two nuts (27) holding brake chamber
(25/26).

25/26
Remove brake chamber (25) / spring brake chamber
(26) and support it so that hoses and connections
(A) are not damaged.
 Change of mechanism 69

Checking play in the slide pins

Measure the play in the outer slide pins (13) by
attaching a magnetic stand complete with a dial
gauge on carrier (3), with the tip of the dial gauge
on point (A) as illustrated. Lift and lower calliper
(2) outside the brake disc and read off the dial gauge.
Repeat the procedure inside the brake disc for the
inner slide pins (13) and measure at point (B). The
method for obtaining a play, measurement must be B
adapted to the ’clock position’ of the disc brake. 13
The example here shows the disc brake in the ’12.00’
position. Max. play 1.0 mm. If remedial measures A
are required, see the section entitled ’Replacing slide 13
pins. slide bearings and seals’.
3

Removing disc brakes

22 22
Remove two of the disc brake’s three retaining bolts
(22) on each side.

Fit pad retainer (7) and secure with bolt (8). Connect
a lifting strap and a suitable lifting device.

Remove the two remaining retaining bolts (22) and 7

lift out the disc brake.

8
70 Change of mechanism

Removing carrier
Position the disc brake in a vice. Use protection jaws

Remove the four protection caps (9), using a

hammer and chisel.

The protection caps (9) must never be re-used.

Disc brake with cups (71): remove two protection

caps (9) and two cups (71).

Remove the four slide pin fixing bolts (10) using 71

special tool P/N81933 (Torx E18 socket).

Press slide pins (13) back (enough to remove carrier

3
(3) from calliper (2)) by rocking carrier (3) to and
fro.

2
NB

Do not use gripping tools or

similar - this will damage the slide
pin sealing surfaces! 9
 Change of mechanism 71

If slide pins (13) are seized in carrier (3), cut threads 3

on the inside of slide pins (13) using an M16x2 tap 2
and special tool P/N81920 ( slide hammer without
yoke) as a puller. Thread tap
7
M16x2

13

P/N81920

3
Remove carrier (3) from calliper (2).
2

NB Only grip on external

surfaces!

Clean the components, removing

any dirt and dust. Use dust rem-
oval equipment or a vacuum
cleaner, but do not use
compressed air - inhaling dust
particles may be harmful to your
health!

Checking slide pin bellows

Check protection caps (9) and bellows (12). (2 per
slide pin).

If there are signs of cracks or other damage,

bellows (12) and protection caps (9) must be
replaced!

If remedial measures are required, see the section

entitled ’Replacing slide pins. slide bearings and 9 12
bellows’.

Disc brakes with cups (71) which act as protection

for the the outer part of slide pins (13) = 6 bellows
(12) and 2 cups (71). Inspect the cups in respect of
leaktightness and damage. Replace cups (71) if 71
required.
72 Change of mechanism

Removing the mechanism 72

Place calliper (2) on a workbench with brake

chamber (25/26) fixing flange facing upwards.
19
Remove the four mechanism fixing bolts (18) and
nuts (19).

18

Using a G-clamp and a suitable socket, press on the

mechanism bearing housing (72) and cut away the
sealant between the cover (33) and the calliper using
a thin knife. Also cut the sealant around the
accessible portion of the joint between the bearing
housing (72) and calliper (2). Remove mechanism
72
(4) from calliper (2).
2
Important!

Do not disturb the mechanism 2

clamps (61) - they are fitted under
high spring tension!
33
Clean the inside of calliper (2) and the sealing
surfaces for mechanism (4). Do not damage the
sealing surfaces!

4
 Change of mechanism 73

Fitting the mechanism

Place calliper (2) on a workbench with brake
chamber (25/26) fixing flange facing upwards. On
the new mechanism, apply a coat of sealant P/ 2
N89653 in a diameter of approx. 8 mm to the sur-
face of cover (33) which seals against calliper (2),
and to bearing housing (72) sealing surface. 72

33

72

Insert mechanism (4) to calliper (2). Ensure that

bearing housing (72) fits correctly in calliper (2).
Secure using a G-clamp.

72

2
74 Change of mechanism

Fit the four bolts (18) and nuts (19) and carefully
tighten until they come in contact with cover (33)
and calliper (2). Remove the G-clamp.

Carefully check that mechanism (4) is correctly

positioned in calliper (2) to avoid damage to cover
(33) - during final tightening of the bolts. 20±3Nm

2
NB
19
The mechanism must be fitted
free of stress!

18
Torque / tighten bolts (18) and nuts (19) diagonally
to 20±3Nm.

Fit special tool (protective cover) P/N81927 in the

brake chamber recess in calliper (2).

P/N
819
27

2
 Change of mechanism 75

Fitting the carrier

2
Return calliper (2) to the vice. Use protection jaws

Clean the contact surfaces in carrier (3) and on pads

(5) (if they are to be re-used) with a wire brush. Do
not grind!

Where slide pins (13) have been removed:

Slide pins (13) of an earlier design (asymmetrical): 13 13

Note the direction of the offset in slide pins (13)
and that the diameter of the end of slide pin (13)
which fits against the carrier boss (3) is less than that
of the end in which the protection cap (9) fits. ( small 13
diameter on the carrier (3) and ’deep’ offset on the
13
brake chamber side). (See illustration, two different
designs.)
13
Later slide pins (13) are symmetrical, both ends
fit into carrier (3). Carriers (3) designed for
symmetrical slide pins (13) cannot accommodate
slide pins with offsets and vice versa. (See illustra-
tion, different designs.) Refer to current spare parts
catalogue to choose spare parts. 13
13
For more information, see the section entitled 3
’Replacing slide pins’.

Apply anti-seize compound, P/N81934, to the in-

ner surfaces of slide pins (13) facing carrier (3).

Press out slide pins (13) so that carrier (3) can be 2

fitted.

Lift carrier (3) into position in calliper (2) and press

in slide pins (13) so that they fit on carrier (3). Do
not damage bellows (12)!

NB Only grip on external surfaces!

Do not damage the seals (12)!
76 Change of mechanism

Lubricate the threads on the four slide pin fixing

bolts (10) using anti-seize compound P/N81934 and
P/N81933
screw them into position. Tighten using a torque
(Torx E18 socket)
wrench and special tool P/N81933 (Torx E18
socket) to 220 ±20 Nm.

Check that carrier (3) slides easily in calliper (2).

10
Max. slide resistance with disc brake (1) fitted on
the vehicle axle: 100N. (See maintenance
instructions)

Tap new protection caps (9) into position in the

outer ends of the slide pins (13) using a 17 mm
socket and an extension. NB The protective cap
must bottom in the slide pin. 220 ±20 Nm

Protective caps (9) for asymmetrical slide pins (13)

feature a central hole, whilst protective caps (9) for
symmetrical slide pins (13) do not.

Slide pins (13) protected by cups (71): Carefully

tap cups (71) into position in calliper (2).

71

71

Socket
Extension
 Change of mechanism 77

Fitting disc brake

Check that the surfaces for fitting to the axle, brake
chamber (25/26) and pads (5) are clean. 7

Fit pad retainer (7) and secure with bolt (8). Connect
a lifting strap and a suitable lifting device.
8
Lift the disc brake into position.

Follow the vehicle/axle manufacturers

recommendations for fitting/tightening bolts (22)
or follow the method as described below:

Lubricate bolts (22) in with anti-seize compound

P/N81934.

Always use new bolts (22) for sizes marked * in

the table below.

Fit one bolt (22) on each side of calliper (2).

Remove the lifting strap, bolt (8) and pad retainer

(7).

Fit the other bolts (22) and tighten all bolts to 100±5 22
Nm and then angle tighten for the relevant bolt as 100 ±5Nm +
set out in the table below. Use a standard protractor. angle tightening

Angle tightening table M16* M18 M20

Pitch
1.0 mm +70° +70° +80°
1.5 mm +50° +50° +55°
2.0 mm +35° +35° +40°
2.5 mm - +30° +35°

Example: Bolt M 16 x 1.5 * = The bolt must not be

Tighten to 100±5 Nm + re-used
50°
Standard
protractor for
angle tightening
78 Change of mechanism

Check the sliding motion of calliper (2) on the slide

pins. Calliper (2) must slide freely on slide pins (13),
max. slide resistance 100N.

Max 100N

13

25/26

▼
B

Fitting brake chamber

Check the internal bellows (A) in brake chamber
(25/26) for cracks and damage and that the external
seal flange (B) against the calliper is intact.

If remedial measures are required, see the vehicle

manufacturer’s instructions.

Remove special tool (protective cover) P/N81927.

P/N89652

Check that the brake chamber (25/26) contact flange

is free from dirt. Put a knob of grease

P/N 89652 in the ball cup on lever (44).

27

Fit brake chamber (25/26) using nuts (27). Tight-

ening torque 180 ±20 Nm.
180 ±20 Nm
 Change of mechanism 79

Fitting pads
Replace pads (5) if they are worn out or if they are
5 5 6
expected to be so by the time of the next service.
Do not replace with pads of a different quality than 7
intended for the installation.

Min. thickness of friction material 2 mm.

If pads (5) are to be re-used, clean their thrust plate 6

(28) contact surfaces and carrier (3) with a wire
3
brush. Do not grind!

Using an 8mm ring spanner, ensure that adjustment

shaft (55) is fully deadjusted. NB Do not use
excessive force, as you may damage mechanism
(4)!
M10 45±5Nm
Check that pad (5) contact surfaces in the disc brake M8 20±3Nm
8
are clean. Fit pads (5), pad springs (6), pad retainer
(7) and secure with bolt (8). Tightening torques M10
45±5Nm and M8 20 ±3 Nm.
80 Change of mechanism

Initial setting
Check that brake disc (A) can be turned freely.

Using an 8 mm ring spanner, turn adjustment shaft

(55) until both pads (5) touch brake disc (A). Then
loosen 1/4 turn to obtain a basic clearance between
pads (5) and brake disc (A). Check that brake disc
can be turned freely. Remove the ring spanner.

IMPORTANT! A
Never use an impact wrench or
other similar device as they may
damage the mechanism!

55
A

15

Lubricate plug (15) inside and out and in adjustment

shaft (55) recesses in calliper (2) with grease
P/N 89652. 55

15

15

Fit protective plugs (15) for adjustment shaft (55).

Check that both plugs (15) are pressed firmly into
position. (See illustration)

15
 Change of mechanism 81

NB Protective plugs (15) protect mechanism (4) from water and dirt. It is
therefore important that these are fitted correctly!

In order to obtain the correct clearance between

brake disc (A) and pads (5), mechanism (4) will
itself make the final fine adjustments during a
number of braking operations.
82 Change of mechanism

Disc brake with spring brake chamber

Make sure that there is sufficient air in the system

(min. 6 bar).

Apply air pressure to the parking brake (min. 6 bar).

Uncage the parking brake spring.

See the vehicle manufacturer’s instructions for more information.

With the service brake engaged and, where

appropriate, with the parking brake released, check
the brake chambers, hoses and connections in
respect of leak-tightness and damage.

Fit the wheels as per the vehicle manufacturer’s

instructions.

NB

Check that the contact surface of the rim and hub

are clean and free from distortion. Follow the
vehicle manufacturer’s instructions for fitting and
tightening torques!

Check that the brake hoses do not foul during full wheel articulation.

Check the wheel so it turns freely with the

parking brake released.

Remove the axle support and the wheel chocks

and lower the axle in accordance with the vehicle
manufacturer’s instructions.
 Change of Brake Chamber 83

Change of Brake Chamber

For number references shown within ( ) that do not appear in this section, see the exploded view

(p. 91-92)

IMPORTANT!
Follow the safety instructions. See the section entitled ’Safety’.
The vehicle manufacturer’s instructions should also be followed.

• Follow the vehicle manufacturer’s instructions to chock the wheels on an axle which is not to be
raised.

• Lift the axle, support, and remove the wheels in accordance with the vehicle manufacturer’s instructions.

Clean the brakes, removing any dirt and dust. Use dust removal equipment or a
vacuum cleaner but do not use compressed air - inhaling dust particles may be
harmful to your health! See ”Cleaning” for instructions.

• Thoroughly clean the joint faces of brake chamber (25) and calliper (2) to ensure that dirt does not get
into the mechanism area when removing the brake chamber.
27

Removing brake chamber

▼
Remove the hose (A). Remove the two nuts (27)
A
holding the brake chamber (25). Remove the brake ▼
chamber (25).

25

Check through the aperture in the brake chamber

attachment flange for moisture / corrosion. If pre-
sent, replace mechanism (4) to avoid early failure.

If action is required see section on ”Replacing 2

mechanism”.
84 Change of Brake Chamber

Fitting brake chambers A

Check that the new brake chamber (25) is of the 25/26

correct design.
▼
There must be an internal bellows (A) on the push B
rod.

Check the external seal flange (B) so it is intact and

seats correctly!

Move the pipe fitting to the new brake chamber (25).

P/N89652
Put a knob of grease P/N 89652 in the ball cup in
lever (44).

Fit the new brake chamber (25) with nuts (27). 27

Tightening torque 180±20Nm.

Fit the brake chamber (25) hose connection.

180 ±20 Nm
 Change of Brake Chamber 85

Remove the drain plug in the chamber housing, which will be turned downwards.

Other drain plugs must remain in position in the chamber housing.

NOTE: If all the plugs remain fitted the mechanism will not operate correctly!

With the service brake engaged and, where

appropriate, with the parking brake released, check
the brake chambers, hoses and connections in
respect of leaktightness and damage.

Fit the wheels as per the vehicle manufacturer’s

instructions.

NB

Check that the contact surface of the rim and hub

are clean and free from distortion. Follow the
vehicle manufacturer’s instructions for fitting and
tightening torques!

Check that the brake hoses do not foul during full wheel articulation.

Check the wheel so it turns freely with the

parking brake released.

Remove the axle support and the wheel chocks

and lower the axle in accordance with the vehicle
manufacturer’s instructions.
86 Change of Spring Brake Chamber

Replacing spring brake chamber

For number references in ( ) in the text which do not appear in this section, refer to the exploded view
(p. 91-92)

IMPORTANT!

Read the safety instructions carefully. See the section entitled ’Safety’.

The vehicle manufacturer’s instructions should also be followed.

• Follow the vehicle manufacturer’s instructions to chock the wheels on an axle which is not to be
raised.

• Lift the axle, support, and remove the wheels in accordance with the vehicle manufacturer’s instructions.

Clean the brakes, removing any dirt and dust. Use dust removal equipment or a
vacuum cleaner

but do not use compressed air - inhaling dust particles may be harmful to your
health! See ”Cleaning” for instructions.

• Clean particularly carefully the joint faces of spring brake chamber (26) and calliper (2).

• Release the parking brake (air on), min. 6 bar in compressed air system.

• Activate the spring caging mechanism of the brake chamber so that the spring is held in its compressed
position. See the vehicle manufacturer’s instructions.

• Apply the parking brake (evacuate the air).

26
 Change of Spring Brake Chamber 87

Removing spring brake chamber

27
Mark and remove the hose connections of the ser-
vice brake (A) and parking brake (B). 26

Remove the two nuts (27) holding spring brake

chamber (25).

Remove spring brake chamber (26).

B
A

Check through the aperture in the brake chamber

attachment flange for moisture / corrosion. If pre-
sent, replace mechanism (4) to avoid early failure.

If action is required see section on ”Replacing

mechanism”.

A
Fitting spring brake chamber
25/26
Check that the park brake spring is caged in
accordance with the manufacturer’s instructions and ▼
B
that the new spring brake chamber (26) is of the
correct design.

There must be an internal bellows (A) on the push

rod. Check the external seal flange (B) so it is intact
and seats correctly!

Move the pipe fittings to the new brake chamber

(25).

Check that the disc brake’s connection flange is free

from dirt.

P/N89652
Put a knob of grease P/N89652 in the ball cup in
lever (44)
88 Change of Spring Brake Chamber

Remove the drain plug in the chamber housing, which will be turned downwards.

Other drain plugs must remain in position in the chamber housing.

NOTE: If all the plugs remain fitted the mechanism will not operate correctly!

Fit the new spring brake chamber (26) with nuts

(27). Tightening torque 180±20Nm.

Fit the spring brake chamber (26) hose connections. 180±20 Nm

NB Do not mix up the hoses!

Release the parking brake and disengage the spring

brake chamber’s caging mechanism so that the
spring is released. Min. 6 bar in compressed air sys-
tem.
27
With the service brake applied and the parking brake
released, check the air connections, hoses and
connectors of spring brake chamber (26) for 26
tightness and damage.

Fit the wheels as per the vehicle manufacturer’s

instructions.

NB

Check that the contact surface of the rim and hub

are clean and free from distortion. Follow the
vehicle manufacturer’s instructions for fitting and
tightening torques!

Check that the brake hoses do not foul during full wheel articulation.

Check the wheel so it turns freely with the

parking brake released.

Remove the axle support and the wheel chocks

and lower the axle in accordance with the vehicle
manufacturer’s instructions.
 Fault-finding 89

Fault-finding
NB Follow safety instructions! See the section entitled ’Safety’.
The vehicle manufacturer’s instructions should also be followed!

Symptoms Action
See the relevant section for remedial measures
No or low braking effort
• Are the pads worn? • Replace the pads.
• Is pad/disc clearance OK? • Conduct initial setting + function checks.
• Is the brake disc OK? • Replace the brake disc (See vehicle manufacturer’s
instructions.)
• Is air pressure in the brake chamber OK? • Implement remedial measures according to vehicle
(Measure with a pressure guage at the brake chamber) manufacturer’s instructions.
• Has the drain plug been removed from the brake • Remove the drain plug located at the lowest point.
chamber housing?

Brake drags/does not fully release

• Does brake pressure remain in the brake chamber • See the vehicle manufacturer’s instructions for information.
when the brakes are released?
• Are all of the spring brake chambers released when • See the vehicle manufacturer’s instructions for information.
the parking brake is off?
• Is pad/disc clearance OK? • Conduct initial setting + function checks.
• Can the pads move freely in the carrier? • Remove the brake pads, clean the pads, carrier and calliper.
• Is the calliper slide function OK? • Replace slide pins/bushings.
• Is the wheel bearing clearance OK? • See the vehicle manufacturer’s instructions for information.
• Has one of the drain plugs been removed from the • Remove the drain plug located at the lowest point.
brake chamber housing?

The brakes pull to one side

• Are the pads worn on one side? • Replace the pads.
• Is pad/disc clearance OK? • Conduct initial setting + function checks.
• Can the pads move freely in the carrier? • Remove the brake pads, clean the pads, carrier and calliper.
• Is there the same pressure in both brake chambers of • See the vehicle manufacturer’s instructions for more infor-
the axle during braking? (Measure with pressure mation.
guage at the brake chambers.)
• Has one of the drain plugs been removed from the • Remove the drain plug located at the lowest point.
brake chamber housing?

Noise/ vibrations from the brake

• Can the pads move freely in the carrier? • Remove the brake pads, clean the pads, carrier and calliper.
• Are the disc brake and its components fixed to axle as • See section entitled ’Replacing slide pins and bushings’.
specified?
• Are there non-permitted cracks/grooves on the brake • See the vehicle manufacturer’s instructions for more infor-
disc? mation.
• Is the brake disc’s runout within specified para- • See the vehicle manufacturer’s instructions for more infor-
meters? mation.
90 Component list

Haldex Disc brakes

Component list
DB 22

1 Disc brake assembly 41 Cross bar

2 Calliper 42 Needle bearing race
3 Carrier 43 Needle bearing, outer
4 Mechanism 44 Lever
5 Pad 45 Retainer
6 Pad spring 46 Rivet
7 Pad retainer 47 Guide pin
8 Bolt 48 Needle bearing, inner
9 Protection cap 49 Circlip
10 Torx bolt 50 Friction disc
11 Bellows ring 51 Pinion
12 Bellows 52 Synchronisation shaft
13 Slide pin 53 Bearing sleeve
14 Slide bearing 54 Adjuster
15 Plug 55 Adjustment shaft
18 Bolt 57 Crown wheel (for item 35)
19 Nut 58 Crown wheel (for item 36)
20 Screw 59 Washer
22 Bolt 60 Circlip
25 Brake chamber 61 Clamp
26 Spring brake chamber 62 Housing (adjuster)
27 Nut 63 Adjustment spring
28 Thrust plate 64 Circlip (small)
29 Clip 64a Circlip (large)
30 Protection spring 66 Friction spring (one-way)
32 Bellows 67 Hub
33 Cover 68 Companion sleeve
34 Circlip 69 Lip seal
35 Adjustment screw (LH threaded) 71 Protection cup
36 Adjustment screw (RH threaded) 72 Bearing housing
37 Bushing 73 Data plate
38 Return spring
Haldex Disc brake DB 22, MK III
For number references shown within ( ), see the exploded view (p. 91-92).
The earlier Haldex Disc Brake MK II has been developed and is now known as the MK III (S/N 043001-).
The improvements in the new model focus on Mechanism (4), Pad retainer (7), Slide pins (13), Carrier (3)
and Calliper (2).

Mechanism (4)
The adjustment shafts (55)/Crown wheel (57/58) bearing in the Calliper (2) have been moved to the
Bearing housing (72), which now forms part of Mechanism (4). The Bearing housing (72), (which is
visible below Brake chamber (25/26) mounting flange) is fixed in Calliper (2). Protection plugs (15), which
sit in Bearing housing (72), are now made entirely of rubber. The clearance function in Adjuster unit (54)
has been changed from being an internal function to being determined by a design clearance in the spline
joint to Hub (67).

Pad retainer (7).

Changed from a brace to an extruded carrier.

Slide pins (13)

Slide pins in the MK II had different internal diameters at the ends, and the internal contact surface of
Torx bolt (10) was offset. The MK III uses symmetrical slide pins (13) (S/N051001-). The length of Torx
bolt (10) has been adapted to accommodate the new Slide pin design (13). Unlike in the MK II, Protection
caps (9) used in the MK III have no central hole.

Carrier (3)
The diameter of Slide pin (13) guides has been adapted to accommodate the changes in slide pin diameter.

Calliper (2)
Now has a ’window’ (located below the Brake chamber mounting flange) where Bearing housing (72) is
fitted, and a fitting groove for a new pad retainer (7). Sections of the manual wholly/partially applicable to
the MK II designare marked with a * on the contents page (page 1).

15 15
72

2 2 15
15

9 9

3 3
91 Exploded view Exploded view 92
28
29 30
26
27
32

34
8
36
7
6 B
29
28
A 37
30 38 42
32 43
4

18 33 34
25 35
27

5 41
42 43
5
9 10
11
12
13 44
14
49
12 11 48 50
51
69 15
55
14 53
11 13 58
12 54
10 12
2 11 9 46 59
60
19
9 10 46 47 48 53 61
11 45
15
12 55 72
13 69 14 45
14 73 13 57
11 52
12 10 12 59
60 61
11 71 51
50
9 49
12 64a 20
11

64
22 68
1 71 66 54
63

3
62

67
22