Meritor Service Caliper ELSA1 and ELSA2 - MM1129

Maintenance manual no.
MM-1129
D-Elsa 1 Reaction Beam Air Disc Brake
Revised November 2008
Service Notes
All rights reserved. Safety Instructions
No part of this publication may be reproduced in any form or
by any means or granted to any third parties without the • Observe the manufacturers safety instructions for jacking up
written permission of ARVINMERITOR. and securing the vehicle
Information contained in this publication was in effect at the time
the publication was approved for printing and is subject to change • Only use original ArvinMeritor parts
without notice or liability. ArvinMeritor Commercial Vehicle Systems • Use only the tools recommended
reserves the right to revise the information presented and to
discontinue the production of parts described at any time. • Observe the following service instructions and notes
• When working on the brake you must ensure that it cannot be

Copyright 2008 by ARVINMERITOR
activated inadvertently
Document No. MM-1129
Edition: November 2008 • Never use compressed air to remove brake dust or for the
purpose of drying. Any type of dust can be injurious to health if
Before You Begin inhaled. Use ArvinMeritor brake cleaner for cleaning the brake.
This publication provides installation and maintenance procedures
• When removing or fitting a complete brake, you should
for the Elsa 1 Reaction Beam Air Disc Brake.
remember it has a dead weight of up to 117lbs (53kg). Use a
The information contained in this publication was current at the lifting system, taking care not to damage the brake.
time of printing and is subject to revision without notice or liability.
• When the servicing has been completed, it is essential that you
You must understand all procedures and instructions before you road test the vehicle and try out the brakes.
begin maintenance and service procedures.
You must follow your company's maintenance and CAUTION You must always renew the brake pads on
service guidelines. both wheels of an axle.Only use brake pads that have been
You must use special tools, when required, to avoid serious approved by the vehicle manufacturer.
personal injury and damage to components.
Meritor uses the following notations to alert the user of possible

CAUTION You must always renew the rotor on both
safety issues and to provide information that will help to prevent wheels of an axle. Only use rotors that have been approved
damage to equipment and components. by the vehicle manufacturer.
WARNING
A WARNING indicates a procedure that you must follow
exactly to avoid serious personal injury.
CAUTION
Access Information on ArvinMeritor's Web
A CAUTION indicates a procedure that you must follow
exactly to avoid damaging equipment or components.
Site
Additional maintenance and service information for ArvinMeritor's
Serious personal injury can also occur.
commercial vehicle systems component lineup is also available at
www.meritorhvs.com
NOTE: A note indicates an operational, procedure or instruction
that is important for proper service. A NOTE can also supply To access information go to Products & Services Icon; from drop
information that will help to make service quicker and easier. down menu click on Literature on Demand. The screen will
display an index of publications by type.
This symbol indicates that you must tighten fasteners to
a specific torque.
2 ArvinMeritor Air Disc Brake D-ELSA 1

Terms used in this manual Warranty
Warranty applies to the air disc brake installed on vehicles for
which it was designed. Warranty is void in the following cases:
Manufacturer:
ARVINMERITOR • Improper use of the vehicle on which the air disc brake is
installed (usage conditions, overloading etc.)
Manual:
Maintenance manual no. MM-1129 • Tampering with vehicle components that may affect brake
performance.
Device:
ELSA 1 Reaction Beam Air Disc Brake. • Use of non-original spare parts.
Technician: • Improper installation, adjustment, repair or modification.

Qualified personnel working on brake maintenance and servicing.
• Poor or improper maintenance (including consumables other
Maintenance and servicing: than those specified).
Maintenance and servicing refer to periodical checks and/or
replacement of air disc brake parts or components. It also refers
to the determining of the cause of a malfunction in order to Further information on warranty conditions may be obtained
restore the initial operating conditions. directly from the manufacturer or by referring to the ArvinMeritor
Operator: web site www.meritorhvs.com
Any person who will use the air disc brake as part of a more
complex device.

Contents
pg. 05 Section 1 - Introduction pg. 43 Section 8 - Brake Replacement
06 Brake designs 44 Brake Removal
45 Brake Fitment
07 Section 2 - How it Works

08 Exploded view - Axial Brake 47 Section 9 - Housing Replacement
09 Parts list - Axial Brake 48 Removing the housing
10 Exploded view - Radial Brake 49 Fitting the housing
11 Parts list - Radial Brake
12 How it works
51 Section 10 - Carrier Replacement
13 Cross section - Brake Assembly
52 Brake carrier replacement
14 Automatic adjustment
15 Cross section - Housing
15 Manual Adjustment 53 Section 11 - Tappet Dust Excluder
Replacement
54 Tappet dust excluder Replacement
17 Section 3 - Manual Adjustment
18 Adjuster stem -
Manual adjustment & De-adjustment 57 Section 12 - Adjuster & Coverplate
Replacement
58 Dismantling
19 Section 4 - Operational Checks
61 Re-assembly
20 Test: automatic adjustment
22 Check sliding action of housing
22 Check slide pin bush wear 65 Section 13 - Guide Sleeve, Dust Excluder &
24 Pad wear check Bush Replacement
25 Rotor inspection & Maintenance 66 Bronze bush removal
67 dust excluder retaining ring assembly
68 Fitting bronze bush
27 Section 5 - Pad Replacement
69 Rubber bush replacement
28 Removing the brake pads
71 Plastic bush replacement
28 Removal - PWWI Type 1
75 Fitting the housing
32 Fitting new pads
33 Refitting the PWWI vers. 1 77 Section 14 - Rotor Re-work
35 Refitting the PWWI vers. 2 78 Rotor Wear Conditions for Rework or Replacement
37 Section 6 - Pad Retaining Plate 79 Section 15 - Servicing & Specifications

Replacement 80 Tightening torque’s
38 Pad retaining plate removal
39 Pad retaining plate fitment 81 Section 16 - Service Diagnosis
82 Service diagnosis
41 Section 7 - CWS (Sensor) Replacement

85 Section 17 - Service Tools
42 CWS (Sensor) Replacement
86 MST 1017 Guide Pin Wear Check Tool
86 MST 1026 Bush Peening Tool
87 MST 1028 Mandrel Kit
ArvinMeritor Air Disc Brake D-ELSA 1 4

Introduction
1
pg. 06 D-ELSA 1 - brake designs

Brake Designs
D-ELSA 1
Type A - Air chamber is arranged axially - Fig. 1.1 and 1.2
Fig. 1.1 Fig. 1.2
Type B - Air chamber is arranged radially - Fig. 1.3 and 1.4
Fig. 1.3 Fig. 1.4
NOTE : “RADIAL BRAKE” is referred to as “PORTAL BRAKE” in NOTE : The descriptions that follow (i.e. functions, servicing the
some applications and some repair kits. brakes etc.) apply to both types with one exception: the direction
of rotation of the adjuster differs in type A and type B.
Refer to Section 3 Manual Adjustment / De Adjustment.

How it Works
2
pg. 08 Exploded view - Axial Brake
09 Parts list - Axial Brake
10 Exploded view - Radial Brake
11 Parts list - Radial Brake
12 How it works
13 Cross section - Brake Assembly
14 Automatic adjustment
15 Cross Section - Housing
15 Manual Adjustment

Exploded View
D-Elsa 1 Axial Brake

Parts List
D-Elsa 1 Axial Brake
Ref Description Ref Description

1 Housing 27 Needle Bearing
2 Carrier 28 Cover plate Screw (M14)
3 Outboard Pad 29 Coverplate Screw (M16)
4 Inboard Pad 30 Short Guide Pin Sleeve
5 Pad Spring 30A One piece Short Guide Sleeve
6 Pad Retaining Screw 31 Long Guide Pin Sleeve
7 Pad Retaining Strap 32 Short Guide Sleeve Screw
8 Locking Plate 33 Long Guide Sleeve Screw
9 Tappet 34 End Cap
10 Tappet Bush 35 Plastic Bush
11 Tappet dust excluder 35A Plain Bush
12 Adjuster Nut 36 Bronze Oval Bush
13 Intermediate Plate 36A Rubber Bush
14 Return Spring 37 Guide Pin dust excluder Retainer
15 Intermediate Gear 37A Guide Pin dust excluder Retainer (with step)
16 Thrust Plate 37B Guide Pin dust excluder Retainer (without step)
17 Adjuster Assembly 38 Guide Pin dust excluder
18 Gasket 39 Rotor
19 Cover Plate 40 Dust Cap (adjuster)
20 Roller 41 Manual Override Adjuster Stem
21 Half Bearing 42 Sleeve Wheel
22 Operating Shaft 43 Friction Spring
23 Operating Shaft Spring 44 Spring
24 Screw 45 Adjuster Ring
25 Plate 46 Multi-Plate Clutch
26 Pin 47 Adjuster Wheel

Exploded View
D-Elsa 1 Radial Brake

Parts List
D-Elsa 1 Radial Brake
Ref Description Ref Description

1 Housing 27 Needle Bearing
2 Carrier 28 Cover plate Screw (M14)
3 Outboard Pad 29 Coverplate Screw (M16)
4 Inboard Pad 30 Short Guide Pin Sleeve
5 Pad Spring 30A One piece Short Guide Sleeve
6 Pad Retaining Screw 31 Long Guide Pin Sleeve
7 Pad Retaining Strap 32 Short Guide Sleeve Screw
8 Locking Plate 33 Long Guide Sleeve Screw
9 Tappet 34 End Cap
10 Tappet Bush 35 Plastic Bush
11 Tappet dust excluder 35A Plain Bush
12 Adjuster Nut 36 Bronze Oval Bush
13 Intermediate Plate 36A Rubber Bush
14 Return Spring 37 Guide Pin dust excluder Retainer
15 Intermediate Gear 37A Guide Pin dust excluder Retainer (with step)
16 Thrust Plate 37B Guide Pin dust excluder Retainer (without step)
17 Adjuster Assembly 38 Guide Pin dust excluder
18 Gasket 39 Rotor
19 Cover Plate 40 Dust Cap (adjuster)
20 Roller 41 Manual Override Adjuster Stem
21 Half Bearing 42 Sleeve Wheel
22 Operating Shaft 43 Friction Spring
23 Operating Shaft Spring 44 Spring
24 Screw 45 Adjuster Ring
25 Plate 46 Multi-Plate Clutch
26 Pin 47 Adjuster Wheel

2 How it Works
How it Works - Fig. 2.1

Two guide pin sleeves (30, 31) are screwed on the brake carrier
(2) by means of guide pin screws (32, 33). The brake carrier is
connected to the stub axle. The housing (1) is mounted so that it
floats on the guide pins. The brake slides on 3 bushes:
- one bronze bush (36) on the side with the short guide pin
sleeve (30)
- two plastic bushes (35) on the side with the long guide pin
sleeve (31)
which are pressed into the housing. The guide pins are sealed
externally by dust excluders (38) and two caps (34).
An alternative design incorporates a rubber bush (36A) in place of

the bronze bush.
The brake is activated via an air chamber (not shown in drawing)

which acts directly on the operating shaft (22). The force
introduced from the air chamber is reinforced by the rotational
movement of the operating shaft (22). This clamping force is
transferred to the inboard pad (4) via the rollers (20) thrust plates
(16), adjuster nuts (12) and the tappets (9).
Once the inboard pad has been applied, the force of reaction
acting through the floating housing (1) pulls the outboard pad (3)
on to the brake rotor (39). The forces created by the friction
between the brake pads and the brake rotor are absorbed by the
brake carrier (2), which is rigidly connected to the stub axle.
The brakes are released by removing the clamping force from the
housing, thus removing the input force.
The housing main return spring (14) and the operating shaft
spring (23) return the clamping mechanism and operating shaft
(22) back to their starting position.
The brake can be fitted with a continuous electronic wear sensor.

See section 4 Fig. 4.16 - The signal from this device is fed into
the vehicles Electronic Braking System.
A Pad Wear Warning Indicator (PWWI) can also be fitted to

indicate that the pads need changing.
See section 4, Figs. 4.17 & 4.18

2 How it Works
Fig. 2.1

2 How it Works
Automatic adjustment b) Operation With Adjustment

The automatic adjuster makes an adjustment to the operation of As a result of pad wear, the running clearance is greater than the
the brake for pad wear. Every time the brake is applied, the built in tolerance. When the brakes are applied, the adjuster ring
system senses whether an adjustment process is required or (45) is rotated within the width of the slot. The built in tolerance
whether the running clearance between pad and rotor is within has been reached, but there is no build-up of clamping force, and
built in tolerance. If the later is the case then adjustment is not additional movement is required. The adjuster ring (45) rotates the
required. The built in tolerance is determined in the design by the adjuster wheel (47) via the multi-plate clutch (46) as the braking
play between the tags of the drive disc of the multi-plate clutch continues. The adjuster wheel's teeth and the intermediate gear
(46) in the slot of the adjuster ring (45), (Fig. 2.2). (15) causes both adjuster nuts (12) to be rotated by the adjuster
wheel. As the tappets (9) are prevented from rotating by the
a) Operation Without Adjustment locking plate (8), the adjuster nuts (12) are wound out from the
The brake is operated without adjusting when the running housing. Both tappets (9) are wound outwards until the clamping
clearance is within the built in tolerance. The rotational movement force exceeds the thread friction torque and causes the multi-
of the operating shaft (22) is transferred to the sleeve wheel (42) plate clutch (46) to slip. This brings the adjustment process to an
through the pin (26) and the connecting block. The sleeve wheel end. This adjustment is not wound back during the return stroke
is linked to the adjuster ring (45) via the friction spring (43); the when the brakes are released. After the adjuster ring (45) has
adjuster ring rotates within the built in tolerance until it comes come into contact with the drive discs of the multi-plate clutch
into contact with the clutch tags. The running clearance has been (46) the friction spring (43) runs free preventing de-adjustment.
traversed and the pads come into contact with the rotor. There is The system is now once again in its starting position.
a build-up of force at the tappets (9). On the adjuster wheel (47)
the thread friction torque of the tappets (9), which has been
generated by the clamping force, is applied to the adjuster nuts
(12). The retaining moment on the adjuster wheel (47) is greater
than the sliding moment of the multi-plate coupling (46), so that
the adjuster nuts are not twisted.

2 How it Works
Manual resetting when replacing pads

(item numbers, see Fig. 2.2)
If the brake pads are worn down to a thickness of 3 mm, the

tappets (9) must be wound back before new pads are installed.
To do this, after removing the dust cap (40), the manual override
adjuster stem (41) is turned in the appropriate direction to
deadjust the brake see Section 3 for direction of rotation.
New pads can now be inserted.
The correct running clearance must be set between the pad and
the rotor. To do this, the manual override adjuster stem (41) is
turned accordingly to adjust the brake see section 5, point 17.
NOTE : The tappets (9) can be turned in both directions using

the override adjuster stem (41).
Brake Identification Plate

The brake identification plate is located adjacent to the manual
adjuster stem cover
Fig. 2.2

Adjuster Stem
Manual adjustment & De-adjustment
3
pg. 18 Adjuster stem - manual adjustment
& De-adjustment

3 Adjuster Stem - Manual Adjustment & De-adjustment
It is essential to turn the adjuster in the correct direction to Direction of rotation:

manually adjust or de-adjust the brake during servicing. It is To adjust or de-adjust the brake refer to the appropriate
independent of the installed position of the brake but different in illustration (Fig. 3.1 to Fig. 3.4).
type A and type B.
CAUTION:
Type A = AXIAL BRAKE
Always de-adjust/adjust the brake carefully by hand with a
Type B = RADIAL (PORTAL) BRAKE suitable wrench. Never exceed a maximum torque of 40 Nm
in either direction and NEVER use power tools.
TYPE A TYPE A
de-adjust de-adjust
adjust adjust
Fig. 3.1 Fig. 3.2
Adjuster is to the left of the diaphragm cylinder. Adjuster is to the right of the diaphragm cylinder.
TYPE B TYPE B
adjust adjust
de-adjust de-adjust
Fig. 3.3 Fig. 3.4
Adjuster is to the left of the diaphragm cylinder. Adjuster is to the right of the diaphragm cylinder.

Operational Checks
4
pg. 20 Test: automatic adjustment
22 Check sliding action of housing
22 Check slide pin bush wear
24 Pad wear check
25 Rotor inspection & Maintenance

4 Operational Checks
Test Automatic Adjustment

1 Remove the dust cap on the adjuster stem (Fig. 4.1).
2 Set a clearance of approximately 2-3 mm between the pad and

the rotor. To do this, turn the adjuster (Fig. 4.2) in the
appropriate direction.
NOTE: To adjust or de-adjust refer to page 18.

3 Position a 10 mm ring wrench on the adjuster stem and do not
hold the wrench (Fig. 4.3). Then operate the brake several times
with approximately 1 to 2 bar. While operating the brake,
observe the direction of rotation of the ring wrench.
Fig. 4.1
NOTE: The direction of the rotation of the ring wrench during the
test is defined on page 21.
Note that as the number of brake applications increases, the

movement of the ring wrench becomes smaller.
Possible faults:
- Ring wrench does not turn
- Ring wrench turns backwards and forwards
If any of the above faults arise, the adjuster or housing assembly

must be replaced, see Section 9 or Section 12.
4 After a successful check set the running clearance between the

brake rotor and pad. To do this, turn the adjuster stem in the Fig. 4.2
appropriate direction until both pads touch the rotor. Then turn
the adjuster back 1/4 turn thus guaranteeing the running
clearance.
NOTE: To adjust or de-adjust refer to page 18.
Fig. 4.3

The direction of rotation of the adjuster stem (see page 18,

point 3) during testing the automatic adjustment is independent of
the installed position of the brake, but differs for type A - AXIAL
and type B - RADIAL (Fig. 4.4 to Fig. 4.7).
TYPE A TYPE A
Fig. 4.4 Fig. 4.5
If the adjuster is to the left of the air chamber (Fig. 4.4), the If the adjuster is to the right of the air chamber (Fig. 4.5), the
wrench turns anti-clockwise to adjust, i.e. the clearance between wrench turns clockwise to adjust, i.e. the clearance between the
the pad and the brake rotor becomes smaller. pad and the brake rotor becomes smaller.
TYPE B TYPE B
Fig. 4.6 Fig. 4.7
If the adjuster is to the left of the air chamber (Fig. 4.6), the If the adjuster is to the right of the air chamber (Fig. 4.7), the
wrench turns clockwise to adjust, i.e. the clearance between the wrench turns anti-clockwise to adjust, i.e. the clearance between
pad and the brake rotor becomes smaller. the pad and the brake rotor becomes smaller.

Checking the Sliding action of the housing

Park the vehicle on hard ground and chock the road wheels. Apply
air pressure to release the park brake and wind off the spring brake
retraction screw (where appropriate). Jack up the axle and fit
suitable axle stands securely. Remove the road wheels and exhaust
all air from the system.
Remove pads as described in section 5
Move the housing backwards and forwards in the direction of the
arrow, as shown in Fig. 4.8. It must be possible to push/pull the
housing easily by hand.
Fig. 4.8
NOTE: Be careful not to damage the guide sleeve excluders

when sliding the housing.
Checking Slide Pin Bush Wear

Radial Test
Remove the pads as described in Pad replacement - section 5.
Fit the ArvinMeritor service tool MST 1017 (Fig. 4.9) to the pad
retaining plate screw hole in the correct position (Fig. 4.10). The
slot in the tool must be parallel to the rotor.
Lock the tool in position with the locknut as shown in Fig 4.11.
Fig. 4.9
Fig. 4.10 Fig. 4.11

Position the brake in the new pad condition. This is achieved by

sliding the brake housing fully in the direction of arrow A (Fig. 4.12)
(Towards the wheel hub)
A
CAUTION:
Take care not to trap fingers whilst sliding the brake.
Mount a dial gauge in a suitable position on the vehicle hub and set
against the service tool as shown in Fig. 4.13. Ensure the hub
cannot rotate
Fig. 4.12
Set the dial gauge to zero.
Fit a torque wrench to the tool in the position as shown in Fig. 4.14.
Apply the torque wrench in the correct direction (Fig 4.14) up to
25Nm without allowing the brake to slide and note the dial gauge
reading.
Remove the torque wrench and fit to the opposite side socket in the
tool Fig. 4.15.
NOTE: DO NOT RESET THE DIAL GAUGE.
Fig. 4.13
Fig. 4.14 Fig. 4.15

Apply the torque wrench in the correct direction (Fig 4.15) up to

25Nm without allowing the brake to slide and note the dial gauge
reading.
NOTE: Take care not to disturb the position of the dial gauge when
applying the torque wrench.
Add the two dial gauge readings together to give total free play
measurement.
NOTE: Max acceptable free play measurement is 2.0mm

Fig. 4.16
Remove the service tool MST 1017.

If this figure is exceeded the guide sleeve pins and bushes require
attention.
Using the correct service kits overhaul the slide pins following the
procedure detailed in Guide Pin replacement - Section 13.
Replace the pads as described in Pad replacement - section 5.
Pad Wear Check
CAUTION: You must always renew the brake pads

on both wheels of an axle. Only use the brake pads that
have been approved by the vehicle manufacturer. Brake Fig. 4.17
pads must be replaced when the lining thickness has worn
to 3mm minimum.
The brake assembly is fitted with a Pad Wear Warning Indicator

(PWWI) or an Electronic Continuous Wear Sensor.
A Wear Sensor is shown in Fig. 4.16
Version 1 of the PWWI is shown in Fig. 4.17

This part is no longer available and is replaced by version 2
Fig. 4.18
Version 2 of the PWWI is shown in Fig. 4.18

This version replaces Version 1 shown in Fig 4.17.
Fig. 4.18

It is essential that even with these devices a visual check is kept Inspect both rotor surfaces for the following conditions.
on the degree of Pad wear - Fig. 4.19
Cracks (Fig 4.20)
A= 20mm new brake pad Cracks that extend through to the vent of a ventilated rotor or
25% through the thickness at the outer edge of a solid rotor:
B= 3mm at the thinnest point. Pads must be changed
Replace the rotor.
immediately for the entire axle.
Fig 4.20
Fig. 4.19
.
Heat Crazing
Rotor Inspection and Maintenance Heat crazing is fine cracks on the rotor's surface. This is a
Check the rotor for grooves, cracks, heat crazing, scoring and normal condition that results from continuous heating and cooling
bluing. of the friction surface. Braking under normal operating conditions
Whilst wearing suitable eye protection remove scale, dirt and can cause cracks to separate and deepen, increasing lining wear.
corrosion etc from around the edge of the rotor. Use an emery There are two types of heat crazing: light and heavy.
cloth if necessary.
Light Heat Crazing (Fig 4.21)
NOTE: One way to remove corrosion is to support a screwdriver Light heat crazing is fine, tight cracks in the rotor's surface.
or scraper on the brake body and rotate the rotor. Continue to use a rotor with light heat crazing.
Rotor
Check that the rotor's thickness dimension meets the
manufacturer's specification and those detailed in the Rotor Wear
Conditions, Section 14. If there is any doubt in the serviceability
of the rotor refer to the vehicle manufacturer for corrective action.
NOTE: If the rotor's thickness dimension is not high enough to

permit expected wear before the next brake pad change: Replace
the rotor.
CAUTION: You must always renew the rotor on both

wheels of an axle. Only use the rotors that have been Fig 4.21
approved by the vehicle manufacturer.

Heavy Heat Crazing (Fig 4.22)

Heavy heat crazing is cracks in the rotor's surface that extend
radialy and have an individual length of up to 75%brake path
width.
Refinish or replace a rotor that has heavy heat crazing.
NOTE: Surface finish after machining should be 5 microns A

maximum.
NOTE: Localised crazing / blue patches / cracking in only one

part of the rotor could be caused by rotor run-out or thickness
variation. Refer to vehicle manufacturer for tolerances. Maximum length = 75% of “A”
Fig 4.22
Scoring (Fig 4.23)

Scoring is deep circumferential grooves that can occur on both
sides of the rotor's surface. If the groove or multiple scores are of
a depth less than 0.5 mm, continue to use the rotor. If the groove
/ scores are greater than 0.5 mm, refinishing the rotor is
recommended.
Refinishing the rotor is recommended before fitting new brake
pads.
"Blue" Rotor (Fig 4.24)

Blue marks or bands on the rotor indicate that extremely high
Fig 4.23
temperatures occurred during operation. Refinishing the rotor is
recommended before fitting new brake pads.
CAUTION Reasons for the excessively high

temperatures must be investigated as this will
adversely affect brake performance and lining wear rate.
Continued operation at excessively high temperatures will
eventually adversely affect brake function.
Fig 4.24

Pad Replacement
5
pg. 28 Removing the brake pads
32 Fitting new pads
33 Refitting the PWWI vers. 1
35 Refitting the PWWI vers. 2

5 Pad Replacement
Removing the Brakes Pads

Park the vehicle on hard ground and chock the road wheels.
Apply air pressure and fully charge the system to ensure the park
brake is fully released. Wind off the spring brake retraction screw
(where appropriate). Jack up the axle and fit suitable axle stands
securely. Remove the road wheels and it is advisable to exhaust
all air from the system. Remove any dirt from the brake assembly.
Ensure the rubber dust excluders fitted to the tappet heads and
guide sleeves are not damaged.
CAUTION:
Never use an air line to blow dust from the brake/rotor area.
Fig. 5.1
If inhaled any form of dust can at best be an irritant, at worst
dangerous. Whenever possible remove dry brake dust with a
vacuum brush. Alternatively wipe the areas with a damp
cloth, never try to accelerate drying time by using an air line.
Note the brake is fitted with a Pad Wear Warning Indicator (PWWI)
There are 2 versions of the PWWI. Both versions are covered in

the following section.
Version 1 PWWI is shown in Fig. 5.1

The removal of this version is covered in 1a to 6a and Figs. 5.2 to
5.7
1a Unscrew and remove the pad retaining clamp screw (Fig. 5.2)
Fig. 5.2
2a Remove the outboard pad spring (Fig. 5.3). Do not strain the
PWWI cable.
3a Carefully remove the plastic block from the outboard pad.

It will help if the pad retaining strap is held down as shown in
Fig. 5.4
Fig. 5.3
28 ArvinMeritor Air Disc Brake D-ELSA 1 Fig. 5.4

5 Pad Replacement
4a Remove the inboard pad spring Fig. 5.5 - Do not strain the
PWWI cable.
5a Remove the plastic block from the inboard pad. Fig. 5.6
6a It is now possible to place the PWWI aside Fig. 5.7
Version 2 PWWI is shown in Fig. 5.8

Removal of this version is covered in 1b to 5b & Figs. 5.9 to 5.13
1b Unscrew and remove the pad retaining clamp screw (Fig.

5.9).
Fig. 5.5
Fig. 5.6 Fig. 5.8
Fig. 5.7 Fig. 5.9

5 Pad Replacement
2b Remove the outboard pad spring Fig. 5.10. Do not strain the
PWWI cable.
3b Carefully remove the plastic block from the outboard pad

(Fig. 5.11)
4b Remove the inboard pad spring. Fig. 5.12 - Do not strain the
PWWI cable.
5b Remove the plastic block from the inboard pad. Fig. 5.13
The PWWI assembly can now be placed aside ensuring that
the cable is not stretched.
7 Remove the dust cap from the manual adjuster override - Fig.
Fig. 5.10 5.14
Fig. 5.11
Fig. 5.13
Fig. 5.12
Fig. 5.14

5 Pad Replacement
8 To remove the brake pads, the adjuster (Fig. 5.15) is turned to

de-adjust the brake until it is easy to remove the brake pads
from the pad aperture.
WARNING: Always de-adjust/adjust the brake

carefully by hand with a suitable wrench. Never exceed a
maximum torque of 40 Nm in either direction and NEVER use
power tools.
NOTE: See Section 3 for the direction of rotation of the adjuster

to adjust or de-adjust the brake.
Fig. 5.15
9 Remove the pads from the aperture (Fig. 5.16).
10 Inspect the dust excluders for damage (Fig. 5.17).

1 - Tappet dust excluders
2 - Guide pin dust excluders (2 pieces)
Renew if necessary, see Section 11 and Section 13.
NOTE: The second guide pin dust excluder (item 7, Fig. 2.1)
cannot be seen in Fig. 5.17.
11 Reset the tappets, secured by a plate (item 1, Fig. 5.18) to

prevent them rotating, by turning the adjuster to de-adjust the
brake. If the limit of the adjustment is reached it is necessary
to turn the adjuster in the opposite direction by between a
Fig. 5.16 minimum of 1/4 of a turn and a maximum of 1 turn.
Fig. 5.17 Fig. 5.18

5 Pad Replacement
NOTE: See section 3 for the direction of rotation of the adjuster

to adjust or de-adjust the brake.
WARNING: Always de-adjust/adjust the brake

carefully by hand with a suitable wrench. Never exceed a
maximum torque of 40 Nm in either direction and NEVER use
power tools.
12 Clean the pad aperture (Fig. 5.19). Examine the brake rotor
for corrosion, grooving, signs of deep crazing and also wear
dimensions as detailed in the Rotor Wear Conditions, section
14
Fig. 5.19 NOTE : We recommend testing the brake at this point in
accordance with section 4.
Fitting new Pads

have been approved by the vehicle manufacturer. Brake
pads must be replaced when the lining thickness has worn
to 3mm minimum.
NOTE: As the range of spares has been combined with disc

brake D3, in some cases, 6 pad springs are included in the repair
set. Two of the springs are not required with D-Elsa.
Fig. 5.20 13 If the rotors are not being changed, use a scraper (Fig. 5.20)
or an old screwdriver to remove the rust from the outer edge
of the rotor (wear protective goggles!). Then finish off the
outer edge of the rotor and the running surfaces with emery
cloth.
14 Check that the housing can move freely on the guide pins,
see section 4.
15 Pull the housing by hand towards the wheel until there is a

gap for the new pad. Fit the outboard pad (Fig. 5.21). If
necessary de-adjust the brake to increase this clearance.
16 Insert inboard pad (Fig. 5.21).
17 Set the running clearance between the brake rotor and the
Fig. 5.21 pad. To do this, turn the adjuster in the appropriate direction
to adjust the brake (refer to Section 3) until both pads are in
contact with the brake rotor. Then turn the adjuster back by
1/4 turn thus setting the running clearance of the brake rotor.
5 Pad Replacement
Fig. 5.22 Fig. 5.24
18 Apply grease and refit the dust excluder (Fig. 5.22).
Refitting the PWWI

Version 1
Refitting of this version is covered in 19a to 26a & Figs 5.23 to
5.29
19a Hold the pad wear assembly as shown in Fig. 5.23 and fit
the plastic block into the inboard pad. Ensure that it is
pressed to the bottom of the slot in the pad backplate.
20a Fit the inboard pad spring - Fig. 5.24
Fig. 5.25
NOTE: the spring is fitted on top of the PWWI wire.
21a Fit the pad retaining strap into the slot in the housing 22a Fit the Pad strap screw and tighten it only sufficient to hold
casting and lever it down against the pad spring - Fig. 5.25 the strap in position. Fig. 5.26
Fig. 5.23 Fig. 5.26

5 Pad Replacement
23a Fit the plastic block into the outboard pad. Fig. 5.27 Ensure
it is pressed fully in.
24a Fit the outboard pad spring. Fig. 5.28 - Note the position of
the PWWI cable.
25a Tighten the pad strap retaining screw to 26 - 29 lbf.ft

(35-40 Nm) Fig. 5.29
26a Before fitting the road wheel, apply the brakes several times
and carry out a visual check of the brake operation.
Running-in instructions
Fig. 5.27
To achieve optimum performance and service life, heavy
braking should be avoided for the first 125 miles.
Fig. 5.28
Fig. 5.29

5 Pad Replacement
Refitting the PWWI

Version 2
Refitting of this version is covered in 19b to 26b & Figs 5.30 to
5.31.
19b Hold the pad wear assembly as shown in Fig. 5.30 and fit
the plastic block into the inboard pad. Ensure that it is
pressed to the bottom of the slot in the pad backplate.
20b Fit the inboard pad spring. Fig. 5.31 -
Note the spring is fitted over of the PWWI wire.
Fig. 5.30
21b Fit the pad retaining strap into the slot in the housing
casting and lever it down against the pad spring. Fig. 5.32
22b Fit the strap screw and tighten it only sufficient to hold the
strap in position. Fig. 5.33
Fig. 5.31
Fig. 5.33
Fig. 5.32

5 Pad Replacement
23b Fit the plastic block into the outboard pad. Fig. 5.34
Ensure it is pressed fully in.
24b Fit the outboard pad spring. Fig. 5.35
Note the position of the PWWI cable.
25b Tighten the pad strap retaining screw to 26 - 29 lbf.ft

(35-40 Nm) Fig. 5.36
26b Before fitting the road wheel, apply the brakes several times
and carry out a visual check of the brake operation.
Fig. 5.34
Running-in instructions
To achieve optimum performance and service life, heavy

braking should be avoided for the first 125 miles.
Fig. 5.35
Fig. 5.36

Pad Retaining Plate Replacement
6
pg. 38 Pad retaining plate removal
39 Pad retaining plate fitment

6 Pad Retaining Plate Replacement
air pressure and fully charge the system to ensure the park brake is
fully released.
Wind off the spring brake retraction screw (where appropriate). Jack
up the axle and fit suitable axle stands securely. Remove the road
wheels and it is advisable to exhaust all air from the system.
Remove any dirt from the brake assembly. Ensure the rubber dust
excluders fitted to the tappet heads and guide sleeves are not
damaged.
CAUTION: Never use an air line to blow dust from the

brake/rotor area. If inhaled any form of dust can at best
be an irritant, at worst dangerous. Whenever possible remove
dry brake dust with a vacuum brush. Alternatively wipe the
areas with a damp cloth, never try to accelerate drying time by
using an air line.
Pad Retaining Plate Removal - Separate PWWI Pad Retaining Plate Removal - Attached PWWI
Remove the pad retaining plate screw and pad retaining plate from Remove the pad retaining plate screw. Note the position / run of the
the brake and discard (Fig 6.1). pad wear cable. Carefully un-clip the pad wear warning cable
retainer from the pad retaining plate. A typical version is shown in
Fig 6.2.
Fig 6.1 Fig 6.2

6 Pad Retaining Plate Replacement
All Types
Clean loose debris from around the pad springs and check correct
positioning. Fig. 6.3 shows the inboard pad spring location and
Fig 6.4 the outboard pad spring location.
Clean loose debris from around the location slot A for the retaining
plate on the brake housing (Fig 6.5)
Important: take care to avoid damage to the pad wear warning
sensor cables or heads.
If there is any doubt in the serviceability of the pad springs, replace
with new or refer to the vehicle manufacturer for corrective action.
Fig 6.3
Pad Retaining Plate Fitment

Carefully clip the pad wear warning cable retainer to the pad
retaining plate where fitted.
Fit the new pad retaining plate and fixing screw, carefully positioning
the pad wear cables where fitted. Tighten the fixing screw to a
torque of 34 - 40Nm.
Charge the system with air. Wind in the spring brake retraction
screw (where applicable).
Apply the brakes 5 times to settle the pads. Check that the rotor is
free to rotate.
Fig 6.4
Fit the road wheels and tighten the retaining nuts to the vehicle
manufacturers' specifications. Jack the vehicle down to the ground
and road test.
A
Fig 6.5

Wear Sensor Replacement
7
pg. 42 CWS (Sensor) Replacement

7 CWS (Continuous Wear Sensor) Replacement
air pressure to release the park brake and wind off the spring brake
retraction screw (where appropriate). Jack up the axle and fit
suitable axle stands securely.
It may not be necessary, but where applicable remove the road
wheels to gain access to the wear sensor. Remove any dirt from the
brake assembly, ensure the rubber dust excluders are not damaged.
CAUTION: Never use an air line to blow dust from the

brake/rotor area. If inhaled any form of dust can at best
be an irritant, at worst dangerous. When ever possible remove
Fig 7.1
dry brake dust with a vacuum brush. Alternatively wipe the
areas with a damp cloth, never try to accelerate drying time by
using an air line.
Sensor Removal
Where applicable, remove the electronic pad wear sensor retaining
screw (Fig 7.1) . Carefully lever out the sensor assembly (Fig 7.2)
disconnect from the vehicle harness and discard.
Sensor Fitment
Clean the sensor access hole and mounting face on the housing and
ensure no debris is allowed to fall into the exposed aperture in the
housing. Fig 7.2
Fit the new electronic pad wear sensor into the housing, ensuring
the sensor stem locates correctly onto the sensor gearbox in the
housing.
NOTE: Ensure the adjuster dust excluder retaining strap is not

trapped under the sensor.
Fit the new retaining screw (Figs 4.1) and tighten to the correct
torque specified in Section 15 Servicing & Specification
Connet the new sensor cable to the vehicle harness
Charge the system with air. Wind in the spring brake retraction
screw (where applicable). Refit the road wheels, remove the axle
stands and lower the vehicle to the ground.

Brake Replacement
8
pg. 44 Brake Removal
45 Brake Fitment

8 Brake Replacement
Brake Removal
Apply air pressure to release the park brake and wind off the
spring actuator retraction screw (where appropriate). Jack up the
axle and fit suitable axle stands securely. Remove the road wheels
and exhaust all air from the system. Remove any dirt from the
Brake assembly, ensure the rubber dust excluders are not
damaged.
CAUTION
Never use an airline to blow dust from the brake/rotor area.
If inhaled any form of dust can at best be an irritant, at
worst dangerous. When ever possible remove dry brake dust Fig. 8.1
with a vacuum brush. Alternatively wipe the areas with a
damp cloth, never try to accelerate drying time by using an
airline.
Important: The brake assembly number should be noted in

order to obtain the correct service kit.
The brake assembly may be fitted with the following wear

indicator, which needs to be disconnected before removing the
Brake.
PWWI (Pad Wear Warning Indicator)

1. Disconnect the PWWI plug where fitted.
CWS (Continuous Wear Sensor) Fig. 8.2

2. Disconnect the Wear Sensor cable where fitted.
3. Remove the air actuator from the Brake housing by removing

the 2 nuts Fig 8.1).
4 Check the diaphragm cylinder gasket for damage (Fig. 8.2),

and if necessary renew (It is essential to follow the vehicle
manufacturer's instructions).
NOTE: support the air chamberunder the vehicle wheel arch in a

position which does not interfere with brake removal or cause
undue strain on the connected air pipe.
5. Cover the exposed air actuator mounting aperture with

adhesive tape to prevent debris etc. entering the housing.
(Fig. 8.3).
Fig. 8.3

8 Brake Replacement
6. Remove the pads as described in section 5 Pad replacement.
7. Remove the CWS (Sensor) as described in Section 7.
NOTE: If the original housing assembly is to be re-fitted blank off

the sensor mounting hole to prevent debris entering the housing
internals.
8.The Brake can now be removed from the axle by removing the
carrier mounting screws following the vehicle manufacturers
instructions.
NOTE: The Brake assembly is heavy, approximately 53kg

(120lbs). Ensure you have the help of an assistant and the weight Fig. 8.4
of the Brake is supported when removing the fixing screws to
avoid possible damage to the threads.
WARNING 2. Lightly grease the operating shaft pocket with the appropriate
When lifting the Brake assembly avoid trapping fingers grease. (Fig. 8.4)
between the Brake housing and carrier which are free to
slide relative to each other. Also prevent any sudden CAUTION
movement, which may result in rapid sliding of the Only use the grease supplied with replacement
components, which may cause damage to rubber dust components/kits. Under no circumstance should any other
excluder areas. type of grease be used.
3. Refit the air chamber to vehicle manufacturers

Brake Fitment specification or as follows:Offer the air actuator to the
1. Ensure all mounting faces are clean and free from corrosion. housing assembly ensuring the mounting faces and push
With the help of an assistant, carefully lower the Brake rod are clean and the push rod is correctly located in the
assembly into position on the axle mounting. Avoid excessive operating shaft pocket. Initially tighten the 2 nuts to a pre
movement of the Brake during location and do not allow the torque of 80 -100 Nm, (this ensures the actuator seals and
Brake to drop into position on the axle, either action could does not distort the non pressure plate). Apply a final
result in damaged to the slide pin dust excluders. torque of 180 - 210 Nm
Fit new fixing screws and torque to the vehicle manufacturers
recommendations. 4. Refit the CWS (Sensor) to the brake as described in Section 7.
5. Refit the Pads & PWWI where appropriate as described in

NOTE: if fitting a new brake assembly, the transit covers must be section 5 Pad replacement.
removed from the Actuator mounting face and CWS (Sensor)
mounting face before fitting the Air Actuator & Sensor. .
NOTE: if replacing the original brake assembly, remove the

temporary protection from the air actuator and CWS (Sensor)
mounting apertures.

Housing Replacement
9
pg. 48 Removing the housing

9 Housing Replacement
Removing the Housing

Apply air pressure to release the park brake and wind off the
spring actuator retraction screw (where appropriate). Jack up the
axle and fit suitable axle stands securely. Remove the road wheels
and exhaust all air from the system. Remove any dirt from the
Brake assembly, ensure the rubber dust excluders are not
damaged.
CAUTION Never use an airline to blow dust from the

brake/rotor area. If inhaled any form of dust can at best be
an irritant, at worst dangerous. When ever possible remove
dry brake dust with a vacuum brush. Alternatively wipe the Fig. 9.1
areas with a damp cloth, never try to accelerate drying time
by using an airline.
Important: The brake assembly number should be noted in

order to obtain the correct service kit.
1 Remove the air chamber from the brake (Fig. 9.1). Cover the
exposed air chamber mounting aperture in the housing to
prevent debris etc. entering the housing. (Fig. 9.2)
2 Check the diaphragm cylinder gasket for damage (Fig. 9.3),

and if necessary renew (It is essential to follow the vehicle
manufacturer's instructions).
NOTE: support the air chamberunder the vehicle wheel arch in a

position which does not interfere with brake removal or cause Fig. 9.2
undue strain on the connected air pipe.
Fig. 9.3 Fig 9.4

Remove the brake pads and PWWI arrangement, see section 5.
4 If a continuous wear sensor is fitted (Fig. 9.4) remove the wear

sensor as detailed in Section 7
NOTE: If the original housing assembly is to be re-fitted blank off

the sensor mounting hole to prevent debris entering the housing
internals.
5 Remove the end caps (Fig. 9.5). Removal will destroy these
caps. Always use new caps.
6 Unscrew the guide pin screws (Fig. 9.6). Fig. 9.5
7 Remove the housing and guide pin sleeves (Fig. 9.7).
Fitting the Housing

1 Fit a new housing (complete with guide pin sleeves and
dust excluders) on the brake carrier, by tightening new
guide pin screws to a torque of 365 to 384 lbs. ft. (495 to
520 Nm) (Fig. 9.6).
NOTE: The one piece sleeve and screw (Fig 9.8) (rubber bush
version) should only be tightened to a torque of 236 to 258lb. ft.
(320 to 350Nm). This figure is lower than the 2 piece version.
Fig. 9.6
Fig. 9.8
Fig. 9.7

2 Check that the housing can move freely over the guide pins
(Fig. 9.9) by moving the frame by hand. If the frame is difficult
to move, unscrew the short sleeve and then tighten it again.
3 Fit pads/PWWI and adjust brake, see section 5.
NOTE: if fitting a new housing assembly, the transit covers must

be removed from the Actuator mounting face and CWS (Sensor)
mounting face before fitting the Air Actuator & Sensor.
NOTE: if replacing the original housing assembly, remove the

temporary protection from the air actuator and CWS (Sensor)
mounting apertures.
4. Refit the CWS (Sensor) to the brake as described in Section 7. Fig. 9.9
5 Refit the air chamber to vehicle as detailed in Section 8.
6 Knock in new end caps (Fig. 9.10).
7 Check the operation of the brake.
Fig. 9.10

Brake Carrier Replacement
10
pg. 52 Brake carrier replacement

10 Brake Carrier Replacement
Removing the Carrier

1 Remove the housing, see Section 9.
2 Unscrew the old carrier from the stub axle (Fig. 10.1).
3. Examine the brake rotor for corrosion, grooving, signs of deep

crazing. Check the wear dimensions as detailed in Section 14
Fitting the Carrier

4 Screw the new carrier on the stub axle, torquing to the vehicle
manufacturer's specifications.
Fig. 10.1
5 Fit the housing, see Section 9.

Tappet Dust Excluder Replacement
11
pg. 54 Tappet dust excluder replacement

11 Tappet Dust Excluder Replacement
Tappet Dust Excluder Replacement
1 Remove the brake assembly as detailed in Section 8 and

transfer to a ssuitable workbench.
2 Unlock and remove the retaining plate (Fig. 11.1).
3 Fully unscrew one tappet (Fig. 11.2) and remove old dust
excluders.
4. Clean the tappet head and dust excluder retaining area on the
housing.
5 Insert new dust excluders into the housing grooved seat

(Fig.11.3).
Fig. 11.1
6 Clean (Fig. 11.4) and grease (Fig. 11.5) the tappet thread.
Fig. 11.2 Fig. 11.4
Fig. 11.3 Fig. 11.5

CAUTION
Only use the grease supplied with replacement
components/kits. Under no circumstance should any other
type of grease be used.
7 Screw the tappet back in (Fig. 11.6), taking care as to whether

this is a left or right hand thread, see below.
Type A - AXIAL (see page 18):
- If the adjuster is to the left of the air chamber, both tappets have
a left hand thread.
Fig. 11.6
- If the adjuster is to the right of the air chamber, both tappets
have a right hand thread.
Type B - RADIAL (see page 18):
- If the adjuster is to the left of the air chamber, both tappets have
a right hand thread.
- If the adjuster is to the right of the air chamber, both tappets

have a left hand thread.
1 8 Fit the dust excluder to the tappet.
NOTE: Do not apply grease to the tappet dust excluder

9 Repeat points 5 to 7 for the second tappet.
Fig. 11.7 10 Use a suitable spacer (1) to adjust both tappets in relation to
the housing (Figs. 11.7 and 11.8).
.
Fig. 11.8

11 Insert the retaining plate and allow it to engage with the

teeth (Fig. 11.9).
12 Lock the retaining plate (Fig. 11.10).
13 After locking the plate measure the distances L1 and L2 (Fig.

11.11) as follows:
Adjust and de-adjust the brake by turning the adjuster just a

few revolutions in both directions to compensate for the play
produced by adjustment. Then adjust the L2 to any dimension.
Measure the distances L1 and L2 and establish the difference
between the two.
Fig. 11.9 Difference = L1 - L2
If the difference is greater than 0.1 mm, unlock the retaining

plate and screw in the tappet, with the larger measurement,
one "tooth". Then repeat 12 and 13.
14 Refit the brake assembly to the vehicle as detailed in Section

8
15 Check the operation of the brake.
Fig. 11.10
Fig. 11.11

Adjuster & Coverplate Replacement
12
pg. 58 Dismantling - (Adjuster removal)
61 Re-assembly - (Adjuster fitting)

12 Adjuster & Coverplate Replacement
NOTE: Before stripping down the brake, check the brake part
number on the identification plate to ensure that the correct kit is
used to rework the brake.
NOTE: Although these brakes appear to be different and the

adjusters are different from axial to radial (portal) brakes and also
handed right to left, the procedures to strip and re-build the
brakes are the same.
Dismantling
1. Remove the brake from the vehicle as detailed in Section 8
Brake replacement.
5. With the brake assembly removed from vehicle, hold in a

suitable fixture, with the cover plate at top of assembly, to aid
removal (Fig. 12.1).
3. Fully de-adjust the brake using the manual override stem (Fig.
12.2) until the tappets are wound back into the housing (Fig.
12.3). This compresses the main return spring inside the
brake for ease of dismantling.
WARNING:
Always de-adjust/adjust the brake carefully by hand with a
Fig. 12.1
suitable wrench. Never exceed a maximum torque of 40 Nm
in either direction and NEVER use power tools.
Fig. 12.2 Fig. 12.3

When the limit of de-adjustment is reached, it is necessary to turn

the adjuster stem in the opposite direction between a 1/2 and 1
full turn so that to prevent the actuation mechanism inside the
brake from locking up.
NOTE: Ensure, where fitted, the CWS (Sensor) is not damaged

when adjusting/de-adjusting the brake.
4. Rrelease the cover plate screws but do not remove (Fig.

12.4).
6. Remove and discard cover plate screws carefully releasing

Fig. 12.4
spring load (Fig. 12.5).
IMPORTANT:
Check the length of the cover plate screws removed before
discarding. This will ensure new screws of the same length
are used on reassembly. The original screws retaining the
coverplate may be cap screws, these can be replaced with
Torx head screws of the same length.
7. Lift cover plate assembly off housing (Fig. 12.6)
NOTE: If the coverplate is to be re-used continue from Step 8. If

a new coverplate assembly is to be fitted go to Step 19.
8. Hold cover plate in secure position and remove clutch

assembly retaining plate and discard screw (Fig. 12.7).
Fig. 12.5
Fig. 12.6 Fig. 12.7

9. Remove clutch assembly from cover plate (Fig. 12.8).
10. Turn cover plate over and hold securely. Lever out adjuster
stem seal (Fig. 12.9).
Clean seal bore and position seal correctly in bore (Figs.
12.10a & 12.10b). Start seal by pressing with fingers.
11. Using a drift of 24mm diameter lightly tap the seal into its
seat (Fig. 12.10a).
12. Turn cover plate over and hold securely.
IMPORTANT
There are 4 versions of the clutch assemblies.
Fig. 12.8
a) Left hand axial clutch assembly.
b) Right hand axial clutch assembly.
c) Left hand radial clutch assembly.
d) Right hand radial clutch assembly.
It is important to identify that the clutch assembly that has been

removed from the brake is compared with the new clutch
assembly to be fitted.
Check the direction of the slip and grip when rotating the old
clutch assembly then compare new clutch assembly to ensure
that the grip and slip directions are the same.
To check which clutch assembly you have is correct for the type
of brake the radial brake has an additional identification slot in the
Fig. 12.9 drive ring, where as the axial clutch assembly does not (Fig.
12.11).
Correct Incorrect Additional Slot
7
22
12
NO
Radial
sc
Axial
Fig. 12.10a Fig. 12.10b Fig. 12.11

Reassembly NOTE: offset of pinhole in slider block to be set as in Fig. 12.13

13. Take clutch assembly from kit and lightly grease end that fits
into cover plate (Fig. 12.12).
15. Fit clutch assembly onto brass slider block using a rod to
CAUTION: steady slider block into assembly. Slide clutch assembly fully
Only use the grease supplied with replacement into cover plate. (Fig. 12.14)
components/kits or that specified by the vehicle 16. Re-fit adjuster retaining plate with new screw and torque to
manufacturer. Under no circumstance should any other type 70 to 85lbf.in. (8 to 10Nm) (Fig. 12.15).
of grease be used.
14. Fit brass slider block onto locating pin the correct way.
Fig. 12.12 Fig. 12.14
SHORT END
LONG END
Fig. 12.13 Fig. 12.15

17. Using a straight edge align with screw holes in cover plate 20. Take new adjuster assembly from kit and remove transit clip
turn slotted ring to visually align with straight edge see Fig. (Fig. 12.18).
12.16.
21. Lightly grease clutch assembly gear wheel end face (Fig.
12.19).
190 200 210
CAUTION:
components/kits or that specified by the vehicle
manufacturer. Under no circumstance should any other type
160 170 180
of grease be used.
Fig. 12.16
18. Check that operation shaft half bearings are correctly seated
in cover plate (Figs. 12.14 & 12.15).
19. Remove adjuster assembly from body (Fig.12.17).
WARNING:
If fitted and after removal of the adjuster assembly do not
rotate the outer plastic gear of the gear box as this will put
the wear senor out of phase with the tappet heads. Fig. 12.18
Fig. 12.17 Fig. 12.19

22. Just before fitting adjuster assembly into housing check the INCORRECT
CORRECT
assembly is correctly assembled and aligned (Figs. 12.20a &
12.20b).
23. Using a straight edge aligned with screw holes as show in

Fig 12.21. Insert adjuster assembly into housing and turn
clutch lugs visually parallel to straight edge.
24. Fit new spring from service kit.
25. Fit new cover plate gasket from service kit.
26. Lightly grease the underside of the cover plate screw heads.
Fig. 12.20a Fig. 12.20b
NOTE: It is important to lubricate the heads of the screws for the
correct torque and angle measurement tightening method.
0 140 150 16
CAUTION:
0 100 110 120 13
of grease be used.
27. Carefully fit cover plate assembly to body.
28. Insert 2 new screws, one at each end of cover plate (Fig.
12.22).
NOTE: It is important that new cover plate screws are used as Fig. 12.21
performance and durability of the brake may be adversely

affected.
IMPORTANT:
Check the length of the new cover plate screws against the
measurement of the original screws removed and replace
with new screws of the same length. There may originally
have been cap screws retaining the cover plate, these can
be replaced with Torx head screws of the same length.
29. Press cover plate down by hand and engage screws in

threads.
Fig. 12.22

30. Screw the 2 screws down incrementing each screw a couple 34. Refit brake to axle as detailed in Section 8 .
of millimetres at a time so that the cover plate is drawn
Torque fixing screws to manufacturers specification.
parallel to the housing, taking care to STOP if there is a
sudden increase in screwing effort before the cover plate is 35. If applicable refit wear sensor after removing plug.
fully down (Fig. 12.22).
36. Refit brake cylinder/air chamber as detailed in Section 8.
31. If a sudden increase in screwing effort is felt remove screws
37. Refit the CWS (Sensor) as detailed in Section 7.
and cover plate, carry out steps 17 and 21 again. Visually
inspect slotted ring and the lugs of the clutch plates on the 38. Refit pads/PWWI as described in section 5.
adjuster assembly for damage.
IMPORTANT:
Use a new adjuster kit if damage is found on any
components.
32. When cover plate is lightly screwed down, contacting the

housing.
Check that brake operates and that the adjuster stem rotates
when the brake is applied by depressing the operation shaft
with a suitable tool.
Insert all remaining cover plate screws and screw down.
33. Torque and angle tightening of all the cover plate screws:
• Torque: 70 to 77lbf.ft (95 to 105 Nm) plus

• Angle: 140° to 150°
ALTERNATIVE: If brake can not be suitably clamped to fully

tighten the cover plate screws, then fully tighten the cover plate
screws after re-fitting brake to axle.
NOTE: It is important that the cover plate screws are tightened

to specification as the performance and durability of the brake will
be adversely affected.

Guide Sleeve, Dust excluder, Retainer
& Bush
13
pg. 66 Bronze bush removal
67 dust excluder retaining ring assembly
68 Fitting bronze bush
69 Rubber bush replacement
71 Plastic bush replacement

13 Guide Sleeve, Dust Excluder, Retainer & Bush
Dismantling
1. Remove the pads/PWWI as described in section 5.
2. Remove the CWS (Sensor) as described in Section 7.
3 Remove the housing assembly as described is Section 9.
Bronze bush Rubber bush NOTE: A number of tools are required to carry out the
procedures detailed below. Service Tool kit MST1028 contains a
Fig. 13.1
series of mandrels to remove and fit the metal guide sleeve
bushes and excluder retainers. Service Tool MST1026 is also
required to stake the bronze bush. Service Tool Kit MST1029
contains additional mandrels requierd to remove and fit the
rubber bush version. The mandrel numbering references for MST
1028 & MST 1029 are detailed in Section 17 Service Tools.
Replacing the Housing Bushes

NOTE: Before stripping down the brake, check the brake part
number on the identification plate to ensure that the correct kit is
used to rework the brake.
Fig. 13.2 Short Guide Pin Sleeve
NOTE: There are 3 types of Short Guide Pin Sleeve arrangement.

It is important to identify the level of brake before attempting to
replace the housing bushes to ensure the correct Service Kit is
used.
There are 2 levels of brake which are fitted with a rubber bush
and 1 level with a bronze bush (Fig. 13.1).
NOTE: The rubber bush and the bronze bush are not
interchangeable.
Bronze Bush Removal
9 Remove the guide pin sleeve and dust excluders (Fig. 13.2).
Fig. 13.3
10 Knock the dust excluder retaining ring out of its seat (Fig.
13.3).

11 Drive out the bush with mandrel 2 from Service Tool kit
MST1028 (Fig. 13.4).
Mandrel 2
Dust Excluder Retaining Ring Assembly
There are 2 levels of housings which require 2 levels of dust
excluder retainers.
Fig. 13.5 shows the old level. For this level the 2 retainers are
identical.
In the later level of retainers the 2 are not identical Fig 13.6).
One for the short guide sleeve and One for the long guide
sleeve. Fig. 13.4
The visible difference between the 2 rings is that one has a step
on the inside diameter. This is to be used on the long guide
sleeve side. (Fig. 13.6)
12 Clean the bore.
13 Pull in the dust excluder retainer using components from

Service Tool MST 1028, as shown in Fig. 13.7a or Fig 13.7b
depending on the level of retainer used, until the retainer is
fully located.
Old level Retainer New level Retainer

Mandrel Mandrel
3 3
Fig. 13.5
Mandrel Excluder Mandrel Excluder

6 Retainer 5 Retainer
Fig. 13.7a Fig. 13.7b
Step
Fig. 13.6

Fitting Bronze Bush

14 Place the new bush on the housing bore (Fig. 13.8)
15 Note the orientation of the bush (shown inset). The 2 notches

of the bush are in the same position as the housing grooves.
(Fig. 13.9)
16 Draw in the bronze bush using components from Service Tool

MST 1028, as shown in Fig. 13.10a or Fig 13.10b,
depending on the level of excluder retainer used.
NOTE: It is important that the bronze bush is not inserted too far
preventing an adequate peen. It should be pulled in until it meets Fig 13.8
the excluder retainer and no further.
The latest bronze bush is 35 mm in length.

The old levels bushes were 40 mm in length.
Always use the latest level bush. It is a direct replacement.
17 Peen the bronze bush into the housing groove using Service
Tool MST 1026, as shown in Fig. 13.11. Fig. 13.12 shows
the bronze bush correctly peened in the bore.
Old level Retainer New level Retainer

Mandrel 3 Mandrel 3
Bush Bush
Fig. 13.9
Excluder Excluder Peened edge

Mandrel 6 Retainer Mandrel 5 Retainer
Fig. 13.10a Fig. 13.10b
Fig. 13.12
Fig. 13.11

Replacement of Rubber bush

18 Remove the combined guide pin sleeve and dust excluders
(Fig. 13.13)
19 Carefully knock the dust excluder retaining ring out of its

seat. (Fig. 13.14)
NOTE: When a rubber bush is fitted the retainer has been

peened into the bore. Therefore it may be necessary to drive out
the retaining ring as shown in Fig. 13.15
20 Drive out the old rubber bush with mandrel 1 from Service Fig. 13.13
Tool kit MST1028 (Fig. 13.15).
21 Clean the bore.
Fig. 13.14
Mandrel 1
Fig. 13.15

22 Insert the new retaining ring into the housing. Using mandrels
12 & 13 from Service Tool MST 1029 together with a screw
M20 x 1.5mm - 90mm long, nut and (preferably) bearing,
draw the retaining ring in until it is flush with the top of the
brake casting. The start and finish positions of the retaining
ring is shown in Fig. 13.16.
23 Remove mandrel 13 and insert mandrel 14 from MST 1029.

Retaining ring flush Mandrel 13 must now be replaced together with the M20 x
with housing Mandrel 1.5mm - 90mm long screw, nut and bearing.
13
NOTE: Ensure mandrel 12 remains in position.
24 Tighten the nut on the M20 screw to peen the edge of the
Finish
retainer into the groove in the housing. (Fig. 13.17)
Start
NOTE: It is essential that this is carried out as the retainer
prevents the rubber bush from moving.
Mandrel M20x1.5 mm 25 Assemble the new rubber bush onto mandrels 9, 10 & 11
12 90 mm long from Service Tool MST 1029 using threaded bar components
Fig. 13.16 8 from MST 1028, detailed in Section 17. and position in
the housing bore (Fig. 13.18)
Mandrel 9
Outer end Peened

into Groove Mandrel 10 Rubber bush
Mandrel 14
Finish
Start
Mandrel 11
Fig. 13.17 Fig. 13.18

26 Pull in the bush as shown in Fig. 13.19 until fully home.
Mandrel 9
Mandrel 10
Rubber bush
Long Guide Pin Sleeve (Plastic Bushes) Replacement

Mandrel 11
NOTE: there are 2 types of plastic bushes used on various brake
assemblies. Fig. 13.20
Fig. 13.19
When replacing bushes use the new style steel backed bush.
Fig. 13.21 shows the 2 design levels of dust excluder retainer

used with the new level of housing design.
Within the new level of dust excluder retaining ring there are 2
rings. These are differentiated by a “step” on one of the rings, this
is to be used with the “long guide sleeve” arrangement (Fig.
13.22).
new level
old level
Fig. 13.20
Step bore (long in guide)

new level
Fig. 13.22
old level
Fig. 13.21

27 Remove the guide pin sleeve and dust excluders (Fig. 13.23).
28 If a circlip is fitted it must be removed and discarded. It is no

longer required (Fig. 13.24)
29 Knock the dust excluder retaining ring out of its seat (Fig.
13.25).
30 Drive out the plastic bush on the cover plate side with
mandrel 1 from Service Tool MST 1028 (Fig. 13.26), taking
care not to damage the bore.
31 Remove the second bush on the rotor side with a mandrel

taking care not to damage the bore.
Fig. 13.23
Fig. 13.24 Fig. 13.25
Mandrel 1
Fig. 13.26

32 Clean the bore.

Mandrel 3 Mandrel 3
NOTE: Use components from Service Tool MST 1028, detailed in
Section 17, to carry out the procedures in steps 33 to 35.
33 Pull in the new plastic bush on the rotor side first (Fig. 13.27a Plastic Plastic
or Fig. 13.27b until the bush is fully home). bush bush
34 Pull in the dust excluder retaining ring (Fig. 13.28a or Fig.

13.28b) until fully home.
NOTE: When pulling in the alternative design of retaining ring

Mandrel Mandrel
(Fig. 8.33b) it will result in the bush being pulled further down the 4 4
bore, this is acceptable.
Fig. 13.27a Fig. 13.27b
35 Pull in the plastic bush on the cover plate side until it is fully
home (Fig. 13.29a or Fig. 13.29b)
Mandrel 3 Mandrel 3 Mandrel 3 Mandrel 3
dust excluder dust excluder dust excluder dust excluder

retaining ring retaining ring retaining ring retaining ring
Mandrel Mandrel Mandrel Mandrel

6 5 6 5
Fig. 13.28a Fig. 13.28b Fig. 13.29a Fig. 13.29b

Guide Pin refitment

36 Smear both guide pin bores (short and long) with the grease
supplied. Gap
37 Fill the gap between the bushes of the long sleeve with
grease (Fig. 13.30).
38 Grease the new sleeves and attach the new dust excluders -
Fig. 13.31 or Fig. 13.32 (Rubber bush).
NOTE: There are differences in surface treatments between the

guide sleeves which gives them the different colour. This is
normal and acceptable.
CAUTION: Fig. 13.30

of grease be used.
NOTE: On the rubber bush brake version, the guide pin sleeve
and screw are combined (see Fig. 13.32).
Fig. 13.32
Fig. 13.31

39 Insert the guide sleeves into the appropriate bores and attach
the dust excluders to the housing retainer and guide pins
(Figs. 13.33 and 13.34)
Fitting the housing

40 Place the housing on the brake carrier (Fig. 13.35).
CAUTION:
Take care not to trap, pinch or damage the guide pin dust
Fig. 13.33
excluders.
41 Use new guide pin screws. Tighten both individual screws to

the torque specified in Section 15 (Fig. 13.36).
NOTE: The one piece sleeve and screw should only be tightened
to the torque specified in Section 15. This figure is lower than
the 2 piece version.
Fig. 13.34
Fig. 13.35 Fig. 13.36

42 Check that the housing can be moved freely on the guide

pins by moving the housing by hand (Fig. 13.37). If the
housing is difficult to move, unscrew the short guide pin
screw and then retighten it again.
43 Fit pads/PWWI and adjust the brake, see section 5.
44 Knock in new end caps (Fig. 13.38).
45. Refit the CWS (Sensor), where applicable, as detailed in

Section 7.
45 Refit the air chamber as detailed in Section 8.
46 Check the operation of the brake. Fig. 13.37
Fig. 13.38

Rotor Wear Conditions
for Rework or Replacement
14
pg. 78 Rotor Wear Conditions For Rework or
Replacement

14 Rotor Wear Conditions for Rework or Replacement
This document explains safe working practices for the limitations

of a rotor life for the D-ELSA Meritor Air Disc Brake, with a pad 48.6mm
back plate thickness of 8mm or above.
45mm
Dimension Detail mm 1.8mm
New Rotor Thickness 45
Minimum Resurfacing Thickness 41 Carrier Abutment Carrier Abutment
Minimum Fully Worn Thickness 39
Rotor
Pad Back Plate Thickness 8
Carrier Rotor Gap 48.6
Minimum Friction Material Thickness 3 New Rotor
New Rotor Condition - Fig 14.1 Condition
The rotor nominal maximum thickness (new condition) is 45mm.
Fig. 14.1
The rotor gap between the carrier abutments of the brake
assembly is 48.6mm nominally. Therefore, if the rotor is central to 48.6mm
the carrier abutments an equal clearance of 1.8mm nominally is 39mm
achieved either side of the rotor. However, due to tolerances the
4.8mm
rotor is not always central to the carrier abutment gap and this
may result in the rotor requiring to be replaced before being worn
Carrier Abutment Carrier Abutment
to the minimum thickness.
Maximum permissible Rotor Wear - Fig 14.2 Rotor

The rotor is permitted to wear to a minimum thickness of 39mm
provided that there a maximum wear of no more than 3mm off
Worn Rotor
anyone rotor face. When equal wear is achieved on both sides of Condition
the rotor, the rotor maintains a central position in the carrier
abutments. Fig. 14.2
Uneven Rotor Wear - Fig 14.3 48.6mm

In many cases where uneven wear takes place the rotor is required 40.95mm
to be replaced before wearing down to the minimum 39mm
4.8mm 2.85mm
thickness. In the case of uneven rotor wear it is important that the
gap between rotor and carrier abutment must not exceed 4.8mm.
Carrier Abutment Carrier Abutment
wheels of an axle. Only use the rotors that have been Rotor
approved by the vehicle manufacturer.
Worn Rotor
WARNING: To ignore these recommendations could Condition
result in severe damage to the wheel end assembly Uneven Wear
due to heat damage from metal pad back plate contacting
Fig. 14.3
the rotor. To wear the pad back plate down to a thickness
where it is possible to trapped between carrier abutments If these recommendations are not followed this negated any
and rotor could cause the wheel to lock at best and pad warranty claim and ArvinMeritor cannot be held responsible
back plates to come out of the brake assembly at worst. for operator neglect.

Servicing & Specifications
15
pg. 80 Servicing schedules
80 Tightening torque’s

15 Servicing & Specifications
Servicing If there is any doubt in the suitability for further service replace
Although there is no routine maintenance of the Brake required it is with new components.
important the following inspections are carried out at the periods Check the brake rotor for signs of heavy grooving, cracking or
specified, or those described in the vehicle manufacturers manual. corrosion as shown in Operational Checks in Section 4 and the
Every 3 months or 20,000 Km. thickness dimension is in accordance with those detailed in Rotor
A visual assessment of pad life remaining should be made. Where rework and replacement Section 14, or the vehicle
a visual pad wear indicator is incorporated into the brake it provides manufacturers recommendations. Replace as necessary.
a quick and simple method of assessing the pad life remaining.
Brake pads should be replaced when the lining thickness has worn
to 3.0 mm.
have been approved by the vehicle manufacturer.
Visually inspect the general condition of the brake assembly for
damage or corrosion, pay particular attention to the guide pin and
piston dust excluders. If there is any doubt in the suitability for
further service replace/rectify in accordance with the vehicle wheels of an axle. Only use rotors that have been approved
manufacturers recommendations. by the vehicle manufacturer.
Every 12 months
CAUTION: Take care not to trap fingers whilst
checking the sliding action of the brake.
Remove the road wheels and brake pads as described in the
Section 5 Pad Replacement Section. Inspect the guide sleeve
and piston excluders and ensure they are undamaged and securely
CAUTION: Only use the grease supplied with the
replacement components/kits, or that specified by the
located. If any of the dust excluders are detached or damaged the
vehicle manufacturer. Under no circumstance should any
relevant area of the brake should be dismantled and the
other type of grease be used.
components examined for corrosion or damage. Replace/rectify in
accordance with the vehicle manufacturers recommendations.
Carry out the Operational Checks in Section 4 of this manual
Tightening Torque’s
Screw lbf.ft Nm
Long Guide Pin Screw 365 - 384 495 - 520
Short Guide Pin Screw - Truck Applications 365 - 384 495 - 520
One Piece Guide Pin - Bus Applications 236 - 258 320 - 350
Pad Retaining Clamp screw 26 - 29 35 - 40
Electronic Wear sensor Screw 25 - 29 33 - 40
Adjuster retaining plate screw 26 - 29 35 - 40
Adjuster retaining plate screw 26 - 29 35 - 40
Cover Plate screws (Torque & Angle) 70 - 77 + 140° to 150° 95 - 105 + 140° to 150°
Brake Carrier screw To Vehicle manufacturer’s specifications
Air Chamber Nuts To Vehicle manufacturer’s specifications

Service Diagnosis
16
pg. 82 Service diagnosis tables

16 Service Diagnosis
Condition Possible Cause Check For Corrections

Brake Drag Incorrect initial adjustment Correct pad-to-rotor Readjust to set the correct rotor-to- pad clearance
clearance
Incorrect pad-to-rotor Automatic adjuster function Replace adjuster, housing or brake assembly
clearance
Spring or service brake Correct operation of air Refer to the vehicle manufacturer's instructions.
not releasing system or air chamber Repair or replace parts as required
Vehicle air system

Air line too short Correct air line length Replace the air line. Refer to the vehicle
manufacturer's instructions
Brake not releasing Damaged guide pin Replace guide pins, excluders and bushes
excluders; Housing should
move back and forth by hand
with linings removed Replace the brake assembly
Water entry or seized Replace operating shaft and air chamber

operation shaft, internal Replace housing or brake assembly and air chamber
Tappets not releasing: Replace tappets, bushes and excluders
Damaged tappet excluders Replace housing or brake assembly
Short brake pad lining Refer to Brake Drag Refer to Brake Drag Refer to Brake Drag
life Damaged rotor surface Cracks or heavy heat spotting Refer to the vehicle manufacturers instructions or
/ banding brake maintenance manual. Repair or replace parts
as required
Vehicle overload Refer to weight limitations on Observe the vehicle manufacturers load
the vehicle identification plate recommendations
Companion brakes do not Inspect the companion Adjust or repair as required

work correctly vehicle
brakes and air system.
Smoking brakes High brake temperature Refer to Brake Drag and Refer to Brake Drag and Short brake pad lining life:
Short brake pad lining life Can be a temporary situation with new or low
mileage pads
Contamination on the Grease, oil, undercoating, Inspect the hub seal. Replace as required
linings or rotor paint, etc., on the linings or
rotor
Clean the rotor and brake assembly
Replace the axle set of pads


Poor stopping power Vehicle air system Correct air pressure at the Have the air system evaluated by a qualified brake
malfunction chamber inlet system specialist
. Long stopping
distances Contamination on the Grease, oil, undercoating, Inspect the hub seal. Replace as required
linings or rotor paint, etc., on the linings or Clean the rotor and brake assembly
. High brake pressures rotor
Replace the axle set of pads
Companion brakes not Inspect the companion vehicle Adjust or repair as required
. Poor driver feel
working correctly brakes and air system
. Vehicle pulls to one Brakes out-of-adjustment Excessive pad-to-rotor Readjust to set the correct pad-to-rotor clearance
side clearance
Automatic adjuster function Replace adjuster or housing assembly

Pads not sliding in Excessive dirt / corrosion in Clean pads and carrier / saddle locations
carrier / saddle pad locations
Excessive wear in pad Fit new carrier / saddle

locations
Incorrect pads installed Refer to the vehicle Replace the axle set of pads
manufacturer for the correct
pads
Spreader / Thrust Plate Spreader / Thrust Plate not Loosen plate fixing screw/s. Reposition plate on
not sliding smoothly in sliding smoothly in carrier / pistons / tappets. Re-tighten screw/s to specified
carrier / saddle saddle torque
Brake seized or sticking Damaged guide pin Replace guide pins, excluders and bushes
on guide pins excluders;
housing should move back
and forth by hand with linings Replace the brake assembly
removed
Vehicle overload Refer to the weight limitations Observe the vehicle manufacturer's load
on the vehicle identification recommendations
plate
Brake noise/ Incorrect pad installation Friction material facing the Correct the pad installation. Replace the pads and
Judder brake not the rotor surface rotor, if necessary
Incorrect pads installed Refer to the vehicle Replace the axle set of pads
manufacturer for the correct
pads


Brake noise/ Brake pads not free to move Corrosion or debris on the pads Clean or replace the pads, if necessary.
Judder, continued in the brake or carrier / saddle pad locations Clean the pad locations on the carrier / saddle
Excessive wear in pad locations Fit new carrier / saddle

Worn brake pads Lining thickness Replace the axle set of pads, if necessary
Loose pads Bent pad retainer or loose pad Replace or tighten the pad retainer
retainer screw
Pad spring damaged or not Correct pad spring installation Install the pad springs
installed
Rotor cracks or excessive Excessive cracking, heat spotting Refer to the vehicle manufacturer's instructions
run-out / thickness variation / banding or run-out / or brake maintenance manual. Repair or
rotor thickness variation replace parts as required
Brake component Check for loose connections and Tighten the connections and fasteners to the
attachments are not fasteners specified torque
installed to specification

Service Tools
17
pg. 86 MST 1017 Guide Pin Wear Check Tool
86 MST 1026 Bush Peening Tool

17 Service Tools
MST 1017 - Guide Pin Wear Check Tool MST 1026 - Bush Peening Tool
This toolis used to check the slide pin bush wear, refer to Section This toolis used to peen the bronze oval guide sleeve bush, refer
4 Operational Checks. to Section 13 Guide Sleeve, Dust Excluder, Retainer & Bush..
Fig. 17.1 Fig. 17.2

17 Service Tools
MST 1028 - Bush and Retainer Mandrel Tool Kit
1 2 3
4 5 6 7
Fig. 17.3

17 Service Tools
MST 1029 - Additional Mandrel Tool Kit (Rubber Bush Brakes)
9 10
11
13
12
14
Fig. 17.4

Meritor Heavy Vehicle Braking Systems
Grange Road, Cwmbran
South Wales NP44 3XU - U.K.
Tel.: +44 (0) 1633 834238 © Copyright 2008 Issued November 2008
Fax: +44 (0) 1633 834191
www.arvinmeritor.com ArvinMeritor Inc. MM1129

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Maintenance manual no.

• When working on the brake you must ensure that it cannot be

Meritor uses the following notations to alert the user of possible

2 ArvinMeritor Air Disc Brake D-ELSA 1

Technician: • Improper installation, adjustment, repair or modification.

3 ArvinMeritor Air Disc Brake D-ELSA 1

07 Section 2 - How it Works

37 Section 6 - Pad Retaining Plate 79 Section 15 - Servicing & Specifications

41 Section 7 - CWS (Sensor) Replacement

ArvinMeritor Air Disc Brake D-ELSA 1 4

ArvinMeritor Air Disc Brake D-ELSA 1 5

Type A - Air chamber is arranged axially - Fig. 1.1 and 1.2

Fig. 1.1 Fig. 1.2

Type B - Air chamber is arranged radially - Fig. 1.3 and 1.4

Fig. 1.3 Fig. 1.4

6 ArvinMeritor Air Disc Brake D-ELSA 1

ArvinMeritor Air Disc Brake D-ELSA 1 7

8 ArvinMeritor Air Disc Brake D-ELSA 1

Ref Description Ref Description

ArvinMeritor Air Disc Brake D-ELSA 1 9

10 ArvinMeritor Air Disc Brake D-ELSA 1

Ref Description Ref Description

ArvinMeritor Air Disc Brake D-ELSA 1 11

How it Works - Fig. 2.1

An alternative design incorporates a rubber bush (36A) in place of

The brake is activated via an air chamber (not shown in drawing)

The brake can be fitted with a continuous electronic wear sensor.

A Pad Wear Warning Indicator (PWWI) can also be fitted to

12 ArvinMeritor Air Disc Brake D-ELSA 1

ArvinMeritor Air Disc Brake D-ELSA 1 13

Automatic adjustment b) Operation With Adjustment

14 ArvinMeritor Air Disc Brake D-ELSA 1

Manual resetting when replacing pads

If the brake pads are worn down to a thickness of 3 mm, the

New pads can now be inserted.

NOTE : The tappets (9) can be turned in both directions using

Brake Identification Plate

ArvinMeritor Air Disc Brake D-ELSA 1 15

ArvinMeritor Air Disc Brake D-ELSA 1 17

It is essential to turn the adjuster in the correct direction to Direction of rotation:

Fig. 3.1 Fig. 3.2

Fig. 3.3 Fig. 3.4

18 ArvinMeritor Air Disc Brake D-ELSA 1

ArvinMeritor Air Disc Brake D-ELSA 1 19

Test Automatic Adjustment

2 Set a clearance of approximately 2-3 mm between the pad and

NOTE: To adjust or de-adjust refer to page 18.

Note that as the number of brake applications increases, the

If any of the above faults arise, the adjuster or housing assembly

4 After a successful check set the running clearance between the

NOTE: To adjust or de-adjust refer to page 18.

20 ArvinMeritor Air Disc Brake D-ELSA 1

The direction of rotation of the adjuster stem (see page 18,

Fig. 4.4 Fig. 4.5

Fig. 4.6 Fig. 4.7

ArvinMeritor Air Disc Brake D-ELSA 1 21

Checking the Sliding action of the housing

NOTE: Be careful not to damage the guide sleeve excluders

Checking Slide Pin Bush Wear