Duco Reaction Beam Air Disc Brake

Maintenance Manual for C and D variants

INDEX
Section Description Page

EXPLODED & SECTION VIEWS 3-4

1 INTRODUCTION 5-7
Brake Application - No Adjustment Required
Brake Application - Adjustment Required
Manual Adjustment

2 PAD REPLACEMENT 8 - 10
Pad Removal
Cleaning & Inspection
Fitting New Pads

3 CALIPER REPLACEMENT 11 - 12
Caliper Removal
Fitting a New Caliper

4 HOUSING REPLACEMENT 13 - 14
Housing Removal
Fitting a New Housing

5 OPERATING SHAFT & ADJUSTER ASSY REPLACEMENT 15 - 20

Component Removal
Brake Re-Assembly
Adjuster Length Sizing

6 TAPPET ASSY, TAPPET HEAD, DUST COVER, RETAINER & BUSH REPLACEMENT 21 - 26
Component Removal
Tappet Bush Replacement
Dust Cover Retainer Replacement
Tappet Assy, Intermediate Gear and Anti-Rotation Plate Replacement
Sensor Gearbox - Initial Setting
Tappet Head and Dust Cover Replacement
Sensor Gearbox - Final Setting

7 WEAR SENSOR GEARBOX REPLACEMENT 27 - 28

Gearbox Removal
Fitting a New Gearbox
Sensor Gearbox Setting

8 GUIDE SLEEVE, DUST COVER, RETAINER & BUSH REPACEMENT 29 - 33

Component Removal
Fitting a New Dust Cover Retainer
Fitting New Brass Bush/s
Fitting New Plain Bushes
Fitting New Guide Sleeves and Dust Covers

9 SERVICING 34
Recommended Service Inspection Periods
Tightening Torque Table

10 SERVICE TOOLS 35

2
DUCO – Typical Exploded Illustration

3
DUCO – Typical Exploded Illustration

4
Duco Reaction Beam Caliper
SECTION 1
Introduction
The air actuated disc brake has been designed to incorporate
a direct mounted air chamber which can be mounted Radially
Fig 1.1), or Axially (Fig 1.2), depending upon installation
requirements.
FIG. 1.1
FIG. 1.2
The caliper, detailed in the exploded view, can be fitted to
either front or rear axles and can be used for vehicle parking
when a service/spring brake chamber is fitted.
The basic operation of the caliper is simple, but it is
important that the features of the load insensitive automatic
adjuster are clearly understood.
It is essential that the correct service procedures are observed
to ensure that the caliper gives satisfactory service
throughout its working life.
How it works
The air chamber/actuator is attached to the caliper body and
operates directly onto the internal operating shaft assembly,
thus removing the necessity for the conventional external
lever and linkage arrangement. Sealing between actuator and
caliper is achieved by seals located in the caliper coverplate
and actuator assembly. The carrier, secured to the vehicle,
straddles the disc and supports the brake pads. The body
assembly slides on two fully sealed guide pins bolted to the
brake carrier.
As the pads wear, adjustment takes place automatically and
independently of load.
NOTE: “Load Independent” means adjustment takes place
under very small clamping forces only, therefore preventing
over-adjustment and minimising air consumption.
Brake application No adjustment required
The actuating mechanism is mechanically driven and
incorporates an eccentric operating shaft, two hardened
rollers, and a twin tappet arrangement. The fully integrated,
automatic, load insensitive adjusting mechanism is situated
to the side of the operating shaft/tappet arrangement. As the
operating shaft rotates it also turns the automatic adjuster via
the adjuster drive pin which engages with the sliding block
incorporated in the adjuster assembly. The adjuster gear
meshes with the adjacent tappet nut and, therefore, is able to
transmit the rotation to the tappet arrangement. An
intermediate gear assembly located between the two tappet
assemblies ensures any rotation is transmitted equally across
both tappets. The tappet screws are prevented from rotating
by an anti-rotation plate.
The sprag clutch arrangement incorporated in the adjuster
assembly has a pre-set clearance which the initial movement
of the op-shaft takes up before any rotation of the adjuster
gear and tappet assemblies can take place. This pre-set
clearance maintains the correct running clearance of the
brake pads.
When the footbrake is applied the air chamber applies a load
to the operating shaft lever arm thus rotating the operating
shaft and adjuster assembly taking up the pre-set clearance.
As the operating shaft rotates further the hardened rollers,
which sit in half bearings in the operating shaft, act against
the two tappet assemblies and thus generate movement of
the tappet assemblies in a linear direction.
This movement generates a clamp force which is transmitted
by the tappet heads evenly across the inner disc pad forcing
it against the brake disc. The reaction force generated causes
the housing to slide on the guide sleeves bolted to the carrier
and clamp the outer pad against the disc.
When the pads contact the disc the clamp load generated in
the tappet assemblies rises rapidly. This results in a rise in
the torque required to rotate the tappet gears. This torque
level overcomes the friction between the multi-plate clutch
assembly causing the clutch plates to slip and, therefore,
preventing any un-necessary adjustment .
5
Duco Reaction Beam Caliper
When the brakes are released the return spring, in NOTE: The brake assembly may be fitted with either a
conjunction with the actuator, return the operating electrical wear sensor, or wear switch. Where applicable
mechanism to its original brakes off position. ensure they are not damaged when using the manual
adjust/de-adjust stem (Fig 1.4a, 1.4b).
Brake application - Adjustment required
The actuator operates in the same manner as described
above and takes up the backlash clearance in the adjuster.
Because the clearance between pads and disc is greater than
the pre-set running clearance, no load is generated to cause
the adjuster clutch to slip.
As a result the multi-plate clutch becomes a solid link,
thereby rotating the adjuster gear which in turn rotates the
adjacent tappet gear and, via the intermediate gear assembly,
the second tappet gear extending the length of the tappet
screw to reduce the pad to disc clearance.
Once the pads contact the disc any further rotation of the
operating shaft will increase the clamp load between pad and
FIG. 1.4a
disc and cause the multi-plate clutch to slip and the adjuster
stops operating, preventing over adjustment.
When the brakes are released, the actuating mechanism
returns, removing the clamp load from the pads. At the same
time the adjuster returns to its original position, providing the
designed pad to disc running clearance. Any further reverse
movement of the adjuster assembly results in the sprag clutch
slipping until the op-shaft reaches it’s rest position. The
friction between the friction spring, return plate and tappet
nuts prevents de-adjustment, therefore, leaving the tappet
arrangement in its newly adjusted position.

Manual Adjustment
The brake adjuster assembly is provided with a manual
override facility which allows the brake to be de-adjusted and FIG. 1.4b
adjusted manually when fitting new pads. To manually adjust
or de-adjust the brake carefully remove the adjuster stem
cover, locate a suitable 10 mm socket spanner on the adjuster
stem (Fig 1.3) and rotate the adjuster stem with the socket
spanner in the appropriate direction.

FIG. 1.3

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Duco Reaction Beam Caliper
To indicate the direction required to adjust or de-adjust the
brake + and - symbols are cast onto the cover plate, on the
front face of the adjuster turret for axial design brake
assemblies, and on top of the adjuster turret for radial design
brakes. (Fig 1.5 & Fig 1.6)

NOTE: Turn the adjuster stem in the direction of the + sign

to adjust the brake. Turn the adjuster stem in the direction of
the - sign to de-adjust the brake. From a fully worn pad
condition it will require approx. 9 full revolutions of the
adjuster stem to fully de-adjust the brake.

IMPORTANT: Always de-adjust/adjust the brake carefully by

hand with a suitable spanner. Never exceed a maximum
torque of 40 Nm in either direction and NEVER use power
tools, air or electric, to de-adjust or adjust the brake.

FIG. 1.5

FIG. 1.6

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Duco Reaction Beam Caliper
SECTION 2
Pad Replacement
Always replace pads in axle sets
A visual pad wear indicator is incorporated into the brake
which provides a quick and simple method of assessing the
pad life remaining.
Note: The position of the visual wear sensor may vary
depending on brake type, however, the function will remain
the same. A typical example is shown in Fig 2.1.
FIG. 2.1
In a new pad condition the end of the indicator stem will
extend past the edge of the housing casting (Fig 2.1).
As the pads wear the length of indicator visible past the edge
of the casting will reduce.
The indicator is incremented with each increment equating
to a level of pad wear (Fig 2.2).
FIG. 2.2
8
Some applications may be fitted with either an electronic
wear sensor (Fig 2.3a), or wear switch (Fig 2.3b) which will
illuminate a lamp on the vehicle instrument panel in a worn
pad condition.
FIG. 2.3a FIG. 2.3b
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 bolt (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 caliper assembly, Ensure the rubber dust covers
fitted to the tappet heads and guide sleeves are not damaged.
WARNING: Never use an air line to blow dust from the
brake/disc 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.
Remove the pad retaining plate bolt and pad retaining plate
from the caliper.
It may be necessary to de-adjust the brake initially to remove
the worn brake pads. Locate a suitable 10mm socket spanner
on the adjuster stem and rotate the spanner in the
appropriate direction, refer to the Manual Adjust section for
details.
IMPORTANT: Always de-adjust/adjust the brake carefully by
hand with a suitable spanner. Never exceed a maximum
torque of 40 Nm in either direction and NEVER use power
tools, air or electric, to de-adjust or adjust the brake.
Duco Reaction Beam Caliper
Remove the brake pads (Fig 2.4) Fit the new outboard pad, (Fig 2.5).

FIG. 2.4
Cleaning and Inspection
With the brake pads removed check the integrity of the guide
pin and tappet dust covers. They should be secure and free
from any signs of damage. Check that the caliper housing
assembly slides freely on the guide pins.
FIG. 2.5
Push the housing back towards the disc until the new pad
contacts the disc face. Continue to de-adjust the brake until
the aperture gap between the tappet heads and the disc face
is large enough to accept the new inboard pad.

WARNING: Take care not to trap fingers whilst checking the NOTE: This dimension should be approximately 29mm -
sliding action of the brake. 31mm Do not exceed the 40Nm maximum torque on the
adjuster shaft.

Examine the brake disc for corrosion, grooving and signs of

deep crazing. If there is any doubt in the serviceability of any With the brake fully de-adjusted it may be necessary to lift
component refer to the vehicle manufacturer for corrective the tappet boots to release any trapped air which may be
action. Whilst wearing suitable eye protection remove all inflating the dust cover (Fig 2.6).
traces of scale, dirt etc., from the pad apertures/abutment
faces and around the edge of the disc, particularly that
encroaching onto the braking area. A scraper, or old
screwdriver, supported on the caliper body whilst the disc is
rotated will remove most of the corrosion. Finish off if
necessary with emery cloth. Remove all traces of scale, dirt
etc., from the pad apertures and abutment faces that may
restrict the movement of the pads and therefore prevent
efficient adjustment of the brake.

Fitting New Pads

Position the new pad springs correctly on the pad backing
plates.
De-adjust the brake until, with the housing pulled across,
there is a sufficient aperture to fit the new outboard pad.

FIG. 2.6

Fit the new inboard pad.

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Duco Reaction Beam Caliper
To adjust the pads locate a 10 mm socket spanner on the
adjuster stem and turn it in the appropriate direction, refer to
the Manual Adjustment section for details.
Continue to adjust the brake until the pads contact the disc.
As the pads wear the length of indicator visible past the edge
of the casting will reduce. The indicator is incremented with
each increment equating to a level of pad wear Fig 2.9.

NOTE: Do not exceed 40 Nm torque on the adjuster stem.

De-adjust the brake by turning the adjuster stem back

1/4 of a revolution. Ensure the brake disc is free to spin.
Ensure the sealing area on the cover plate is clean. Always
replace the adjuster stem cover (Fig 2.7).
Refit the pad retaining plate and torque the fixing bolt to 33 -
40 Nm.

FIG. 2.9

Charge the system with air. Wind in the spring brake

retraction bolt (where applicable). Refit the road wheels,
remove the axle stands and lower the vehicle to the ground.

NOTE: Before driving the vehicle or applying the park brake,

apply the service brake five times at low pressure to ensure
correct adjustment of the pads.

FIG. 2.7
In a new pad condition the end of the indicator stem will
extend past the edge of the housing casting (Fig 2.8).

FIG. 2.8

10
Duco Reaction Beam Caliper
SECTION 3
Caliper Replacement
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 bolt (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 caliper assembly, ensure the rubber dust covers are
not damaged. Remove the air chamber from the caliper
housing and support under the vehicle wheel arch in a
position which does not interfere with caliper removal or
cause undue strain on the connected air pipe. Cover the
exposed air chamber mounting aperture in the housing
assembly to prevent debris etc. entering the housing.
WARNING: When lifting the caliper assembly avoid trapping
fingers between the caliper housing and carrier which are free
to slide relative to each other. Also prevent any sudden
movement which may result in rapid sliding of the
components which may cause damage to rubber dust cover
areas.
Caliper Fitment
Ensure all mounting faces are clean and free from corrosion.
With the help of an assistant, carefully lower the caliper
assembly into position on the stub axle mounting. Locating
pins (Fig 3.2a – not fitted to all brakes), or counter bores (Fig
3.2b) in the carrier are provided to aid assembly.

WARNING: Never use an air line to blow dust from the

brake/disc 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 areas
with a damp cloth, never try to accelerate drying time by
using an air line.

Caliper Removal
Where applicable, remove the electronic pad wear sensor
retaining screw and carefully lever out the sensor assembly
(Fig 3.1a).
When switch is fitted, do not remove switch from brake, pull
out connector (Ref. Fig. 3.1b)

FIG. 3.2a FIG. 3.2b

Avoid excessive movement of the caliper during location and

do not allow the caliper to drop into position on the stub axle,
either action could result in damaged dust covers. Fit new
retaining bolts and torque to the vehicle manufacturers
recommendations.
Lightly grease the operating shaft pocket with the
appropriate grease.

NOTE: Only use the grease supplied with replacement

components/kits or that specified by the vehicle
manufacturer. Under no circumstance should any other type
of grease be used.

FIG. 3.1a FIG. 3.1b Offer the air chamber to the housing assembly ensuring the
Remove the pads as described in the Pad Replacement section. mounting faces and push rod are clean and the push rod is
correctly located in the operating shaft pocket.
IMPORTANT: The caliper assembly is heavy, approximately
36kg (80lbs) - C. DUCO and 53kg (117lbs) - D.DUCO. Ensure
you have the help of an assistant and the weight of the
caliper is supported when removing the fixing bolts to avoid
possible damage to the threads.

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Duco Reaction Beam Caliper
Secure the air chamber to the housing assembly and torque
to the vehicle manufacturers recommendations.

Fit the new pads as detailed in the pad replacement section.

Where applicable fit the electronic pad wear sensor, ensuring
that the sensor stem locates correctly onto the sensor gearbox
in the housing.

When a wear switch is fitted reconnect the connector

ensuring that no water or debris is present in the connector

NOTE: Ensure the sensor access hole and mounting faces are
clean and the adjuster dust cover retaining strap is not
trapped under the sensor.

Tighten the retaining screw to the correct torque.

NOTE: There are two types of wear sensor cable retaining

screw currently in service, M8 self tap design 14 - 20Nm and
standard M10 hex head screw 33 - 40Nm.

Charge the system with air. Wind in the spring brake

retraction bolt (where applicable). Refit the road wheels,
remove the axle stands and lower the vehicle to the ground.

NOTE: Before driving the vehicle or applying the park brake,

apply the service brake five times at low pressure to ensure
correct adjustment of the pads.

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Duco Reaction Beam Caliper
Fitting a New Housing
SECTION 4 Lightly lubricate the inner surface of the new guide sleeve
dust covers with grease and ensure they locate correctly on
Housing Replacement the housing dust cover retainers. Apply grease to the new
guide sleeves and housing guide sleeve bores.
Removing the Housing
Support the vehicle and remove the air chamber as detailed NOTE: Only use the grease supplied with replacement
in the caliper removal section. Remove the electronic pad components/kits or that specified by the vehicle
wear sensor, where applicable, and the brake pads as manufacturer. Under no circumstance should any other type
detailed in the Pad Replacement section. Tap and lever out of grease be used.
the guide pin caps (Fig 4.1).

Fit the guide sleeves into the new caliper housing from the
actuator side (Fig 4.2).

FIG. 4.1
FIG. 4.2
NOTE: Depending on installation it may be necessary to
pierce the centre of the end cap to lever out effectively.
Carefully push the guide sleeves through the dust covers (Fig
4.3) ensuring the location of the dust covers on the housing are
Loosen the guide pin bolts. Remove the caliper assembly and not disturbed.
transfer to a suitable workbench and place upside down with
the carrier uppermost. Remove the guide pin bolts and
carefully disengage the guide sleeve dust covers from the
carrier location and lift the carrier from the housing assembly.

NOTE: Ensure the visual indicator is retained before

separating the caliper housing and carrier. This will prevent
the spring load ejecting the indicator.

Clean and inspect the carrier for signs of damage or wear

paying particular attention to the pad abutment areas and
guide sleeve location points. If any doubt exists as to the
suitability for further service replace with a new carrier. Clean
and inspect the brake disc as detailed in the Pad
Replacement section.

FIG. 4.3

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Duco Reaction Beam Caliper
Wipe off any excess grease from the end of the guide sleeve
(Fig 4.4).

FIG. 4.4
Carefully lower the carrier into position on the housing
assembly and ensure the guide sleeves locate in the counter
bores machined in the carrier (Fig 4.5).
FIG. 4.6
Fully tighten the guide pin bolts to a torque of 450 - 500Nm.
NOTE: If a suitable fixture is not available to hold the caliper
securely the final tightening of the guide pin bolts, to 450 -
500 Nm, can be done when the brake assembly has been re-
fitted to the vehicle. Ensure there is sufficient access under
the vehicle to carry out the procedure, and fit the guide pin
caps, if this option is taken.
Check again the free movement of the housing assembly on
the guide pins. Using a copper faced mallet, carefully tap one
of the new guide pin caps into the housing until it retains
itself. Using a suitable size tool, or hexagon socket (Fig 4.7),
tap the cap into the bore until it is flush with the top of the
guide sleeve turret (Fig 4.8).
Re-assemble the brake as detailed in the Caliper
Replacement section.

FIG. 4.5
Fit the new guide pin bolts and torque to an initial torque of
50Nm only at this stage. FIG. 4.7

NOTE: Take care not to damage the guide pin or tappet dust
covers when locating the carrier on the housing.

Locate the guide pin dust covers on the carrier.

Carefully slide the carrier slightly to check the secure location
of the dust covers (Fig 4.6).
Slide the carrier backwards and forwards several times to
check the smooth movement of the housing on the guide
pins. FIG. 4.8

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Duco Reaction Beam Caliper

SECTION 5
Operating Shaft & Adjuster Assy
Replacement
Remove the caliper as detailed in the caliper replacement
section. Transfer to a suitable workbench and secure in a
vice.
Using the manual adjuster stem, adjust the tappet
assemblies to the maximum adjust position

NOTE: Although it is not necessary to remove the tappet

heads when replacing the op-shaft or adjuster assembly, it is
advisable. Should the tappet assemblies become displaced
whilst the coverplate is removed they may have to be
removed and re-set. It may be difficult to remove the tappet FIG. 5.2
heads at that stage.
If the original op-shaft is to be re-fitted with new half
bearings and rollers, lift out the old rollers (Fig 5.3) and
Component Removal carefully lever out the old half bearings (Fig 5.4).
Loosen the coverplate bolts working in a diagonally opposite
sequence to maintain the coverplate level to the housing.
Leaving two diagonally opposite bolts loose but in place,
remove the remaining bolts.
Loosen the remaining two bolts until there is no thread
engagement in the housing. Holding the op-shaft and
coverplate, as shown in Fig 5.1, carefully lift the assembly
from the caliper housing.

FIG. 5.3

FIG. 5.1

Place the coverplate on the workbench. Remove the gasket

and two remaining coverplate bolts.
Carefully lift the op-shaft, together with the adjuster
assembly, out of the coverplate. Dis-engage the op-shaft
adjuster drive pin from the adjuster sliding block (Fig 5.2).
FIG. 5.4

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Duco Reaction Beam Caliper
Clean the op-shaft and examine for any signs of damage or IMPORTANT: Do not remove or disturb the tappet
excessive wear. If any doubt exists in the suitability for assemblies, anti-rotation plate, intermediate gear or wear
further use, replace with a new assembly. sensor gearbox unless they need to be replaced.
Remove the two needle bearings from the coverplate and
using a suitable tool, drift out the actuator seal from the op-
If any doubt exists in the suitability for further use replace
shaft side of the coverplate (Fig 5.5).
with new components.

Re-Assembly
NOTE: Only use the grease supplied with replacement
components/kits or that specified by the vehicle
manufacturer. Under no circumstance should any other type
of grease be used.

Lightly grease the new adjuster stem seal and press into
position in the coverplate (Fig 5.7). This should be possible
with hand pressure.

FIG. 5.5
Using a suitable screwdriver carefully lever out the adjuster
stem seal (Fig 5.6).

FIG. 5.7

NOTE: Ensure the seal is fitted the correct way round when
pressing into the coverplate,
Fig 5.8 CORRECT Fig 5.9 INCORRECT

CORRECT INCORRECT

FIG. 5.6

Clean the coverplate with a suitable Brake Cleaner and

examine for damage or excessive wear.

FIG. 5.8 FIG. 5.9

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Duco Reaction Beam Caliper
Locate the new actuator seal into the cover plate (Fig 5.10)
FIG. 5.10
Using a suitable drift tool carefully tap into position (Fig 5.11).
FIG. 5.11
Fit the new needle bearings into the coverplate locating them
at the outer edge of each op-shaft recess (Fig 5.12).
FIG. 5.12
If the original op-shaft is to be re-used fit new half bearings
into the shaft ensuring that the small pips on the rear side of
the bearings locate correctly in the holes provided in the op-
shaft. Liberally grease the half bearings and fit the new rollers
into position. Apply further grease to the rollers. This will help
keep the rollers in position and thus aid re-assembly of the
coverplate.
NOTE: Only use the grease supplied with replacement
components/kits or that specified by the vehicle
manufacturer. Under no circumstance should any other type
of grease be used.
Ensure the adjuster assembly sliding block, and both ends of
the adjuster shaft are well greased and engage the op-shaft
adjuster drive pin into the sliding block (Fig 5.13).
FIG. 5.13
Carefully fit the op-shaft assembly and adjuster assembly,
together, into the coverplate. When correctly located it should
be possible to gently operate the op-shaft by hand (Fig 5.14)
and observe the adjuster assembly rotating.
FIG. 5.14
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Duco Reaction Beam Caliper
Check the needle bearings remain correctly fitted and the
tangs on the rear of the bearing abut the coverplate (Fig 5.15)
Engage the two coverplate bolts and slowly tighten in
sequence keeping the coverplate parallel to the housing.
Fit the remaining coverplate bolts and tighten to;
C. DUCO: 7 bolts M12 - torque to 110 - 130Nm.
D. DUCO: 8 bolts M14 - torque to 190 - 210Nm.

Operate the op-shaft as shown in Fig 5.17.

When depressing the op-shaft resistance should be felt, when
released the op-shaft should return to the original position

FIG. 5.15

Fit two of the coverplate bolts into the coverplate, diagonally

opposite and fit a new gasket over the bolts into position on
the coverplate.
Holding the coverplate assembly, with op-shaft and adjuster,
as shown (Fig 5.16) carefully re-fit into position on the caliper FIG. 5.17
housing ensuring the adjuster gear engages correctly with
the gear on the tappet. If necessary rotate the adjuster stem NOTE: While applying the op-shaft you may here a click as
slightly to provide engagement. the sensor gearbox engages with the adjuster gear. This does
not indicate a problem.

Adjuster length sizing

NOTE: the operation of setting the adjuster length does not
apply to later level adjuster assemblies (Fig 5.18), or when
removing and re-fitting an existing early level adjuster
assembly (Fig 5.19). It is necessary when fitting a
NEW early level adjuster assembly.

FIG. 5.16

Check the rollers do not become detached from the op-shaft

during this operation and also that the needle bearings
remain correctly fitted and the tangs on the rear of the
bearing abut the coverplate.

FIG. 5.18 FIG. 5.19

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Duco Reaction Beam Caliper
Locate the Meritor setting tool, Part No. MTB 1002 onto the Locate a suitable torque wrench on the hexagon nut and
head of the adjuster stem (Fig 5.20 & 5.21). tighten to 8Nm (Fig 5.24)

FIG. 5.20 FIG. 5.21

FIG. 5.24
Slide the outer barrel of the tool until it abuts against the Remove the torque wrench and set the tool pointer to align
adjuster housing turret (Fig 5.22). with one of the indicator marks on the tool head (Fig 5.25)

FIG. 5.25

Using a suitable wrench turn the hexagon nut, and thus the
FIG. 5.22 tool head, clockwise through two divisions indicated on the
Wind the top hexagon nut down to the sleeve until finger tool head (Fig 5.26) .
tight (Fig 5.23).

FIG. 5.26
FIG. 5.23 Remove the adjuster sizing tool.

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Duco Reaction Beam Caliper
Position a DTI on the caliper housing with the indicator If the reading falls outside these tolerances it may be
plunger located against the adjuster stem head (Fig 5.27). necessary to repeat the procedure, refer to the detail below
and follow the recommended action.

DTI reading 0.00mm

Using the meritor setting tool MTB 1002, repeat the setting
procedure detailed above but turn the hexagon nut through
one division on the tool head only.

DTI reading 0.01mm - 0.049mm

Using the Meritor setting tool MTB 1002, repeat the setting
procedure detailed above but turn the hexagon nut/tool head
through Half a division indicated on the tool head.

DTI reading above 0.020mm

This measurement indicates there may be a problem which
could be associated with the adjuster assembly or caliper
housing assembly. The caliper therefore requires examination
FIG. 5.27 and assessment.

Using a suitable screwdriver located in the adjuster stem

When the adjuster setting procedure has been carried out
undercut, push the adjuster stem into the caliper housing
sucessfully re-assemble the brake as detailed in the Caliper
until a resistance is felt (Fig 5.28).
Replacement section.
Refit the caliper assembly as detailed in the Caliper
Replacement section.

FIG. 5.28

IMPORTANT: Light finger pressure on the screwdriver is

required. Excessive force applied will result in a false reading
Set the DTI gauge to 0 then carefully release the pressure on
the screwdriver allowing the adjuster stem to return to its
original position.
Take the reading from the DTI gauge.
The reading should be within the range 0.05mm - 0.2mm If
within this tolerance band no further setting is required.

20
Duco Reaction Beam Caliper
Using suitable pliers carefully remove the circlip retaining the
SECTION 6 tappet head to the tappet screw (Fig 6.3)
Remove the tappet head, (Fig 6.4).
Tappet, Tappet Head, Dust Cover,
Retainer & Bush
Component Removal
Remove the caliper as detailed in the caliper Replacement
section and transfer to a suitable workbench. Push the
housing assembly inboard and, using the manual adjuster
stem, adjust the tappet assemblies to the maximum adjust
position to gain good access to the tappet head area (Fig 6.1).

FIG. 6.3

FIG. 6.1
Thoroughly clean around the tappet dust cover area with a
suitable Brake Cleaner or clear methylated spirits. Carefully
detach the tappet dust cover from the housing and peel back
over the tappet head to remove (Fig 6.2).

FIG. 6.4

Examine the tappet head for signs of damage and if in any

doubt in the suitability for further service replace with new
components.

NOTE: Do not allow dirt or debris into the exposed

tappet/housing areas.

FIG. 6.2 Remove the coverplate, adjuster assembly and op-shaft

Discard the old dust cover. assembly as detailed in the op-shaft replacement section

21
Duco Reaction Beam Caliper
Holding the components together (Fig 6.5) carefully remove
the tappet assemblies, with the intermediate gear and anti-
rotation plate, from the housing.
FIG. 6.5
Remove the friction and return springs (Fig 6.6).
FIG. 6.6
Using a screwdriver carefully tap the dust cover retainers out
of the housing (Fig 6.7). Using Meritor service tool Part No.
MTB 1000, pull both tappet bushes from the housing.
NOTE: The bushes have a flanged head and must be pulled
out from the actuator side of the housing (Fig 6.8).
22
FIG. 6.7
FIG. 6.8
Tappet Bush Replacement
Thoroughly clean the internal cavity, and tappet bush bores
of the housing. Examine the wear sensor gearbox for any
signs of damage and if any doubt exists in the suitability for
further use replace with a new unit.
Locate one of the new bushes into the tappet bore section of
the housing and using the Meritor service tool Part No. MTB
1000, (Fig 6.9) carefully pull the bush into the bore until the
shoulder of the bush abuts against the housing (Fig 6.10).
Repeat this operation for the second bush.
NOTE: The bushes have a flanged head and, therefore, must
be pulled in to the housing from the op-shaft side.
Duco Reaction Beam Caliper
Dust Cover Retainer Replacement
Fit one of the new retainers into the housing using the
Meritor tool MTB 1000, (Fig 6.11). Carefully pull the retainer
into the housing until it abuts against the shoulder (Fig 6.12).
Repeat this operation for the second retainer

IMPORTANT: Do not apply too much force when pulling the

bush/s into the housing as this may result in damage to the
dust cover retainer or bush.

FIG. 6.9

FIG. 6.12

Tappet Assembly, Intermediate Gear and Anti-rotation plate

Replacement

IMPORTANT: Before fitting the new tappet assemblies into

the housing they must be adjusted to the correct length.

FIG. 6.10 Using a suitable vernier gauge measure the length of the
new tappet assemblies (Fig 6.13). If necessary wind the
tappet body in, or out to adjust to a dimension of 85mm, +/ -
0.1mm.

FIG. 6.11 FIG. 6.13

23
Duco Reaction Beam Caliper
IMPORTANT: This dimension is critical. Any deviation across Sensor Gearbox - Initial Setting
the tappets will result in taper wear.
Wind the sensor gearbox in the appropriate direction, LH or
RH thread, until the gearbox centre shaft is level with the
Apply grease to the friction (larger diameter) spring and insert inner face of the gear (Fig 6.15).
into the housing. The grease will help to hold the spring in
the correct position in the housing counterbore
IMPORTANT: Do not wind the gear too far, this will cause the
Lightly grease the tappet bushes and tappet assemblies. inner shaft to become dis-engaged from the sensor gear. If
Liberally grease the intermediate gear assembly. this occurs the sensor gearbox must be removed and
Assemble the tappet assemblies, intermediate gear and anti- replaced.
rotation plate together. It may be necessary to rotate one of
the tappet assemblies by up to half a gear tooth to achieve
correct engagement. Fit the return spring into the
intermediate gear recess between the tappet assemblies.

Holding the components together carefully fit into the

housing (Fig 6.14) ensuring that the tappet assemblies locate
correctly in the tappet bushes.

FIG. 6.15

Re-assemble the op-shaft and adjuster and refit the coverplate

as detailed in the op-shaft replacement section.

Tappet Head and Dust Cover Replacement

Before fitting the tappet head to the tappet screw ensure a
new circlip is located correctly in the tappet head (Fig 6.16).

FIG. 6.14

Some brakes may include a secondary counterbore for

location of the return spring (smaller diameter spring). If
applicable check the position of the spring to ensure it
locates correctly in the housing counterbore. If it is
incorrectly seated carefully lift into position with a small
screwdriver.

NOTE: When tappet assemblies have been removed/replaced

it is necessary to reset the wear sensor gearbox following the
initial and final setting procedures detailed .

FIG. 6.16

24
Duco Reaction Beam Caliper
Carefully fit the new dust cover onto the housing retainer (Fig
6.17).

FIG. 6.19
Ensure that dust cover square section bead is located
FIG. 6.17 correctly on both tappet head and housing retainer (Fig 6.19)
Press the tappet head onto the tappet screw, by hand, (Fig
6.18) and ensure that it is retained by the circlip. Carefully
locate the tappet dust cover on to the tappet head.

FIG. 6.20

Sensor Gearbox - Final Setting

FIG. 6.18 With the caliper correctly assembled it is necessary to

complete the sensor gearbox setting before re-fitting the
caliper assembly to the vehicle.
Fit the Meritor service tool Part No. MTB 1003, setting spacer
block into the pad aperture and using the adjuster manual
override stem adjust out the tappets until they abut the
spacer block (Fig 6.20).

25
Duco Reaction Beam Caliper
Insert the Meritor gearbox service setting tool Part No. MTB
1003, into the sensor aperture in the coverplate and ensure it
seats correctly in the counterbore (Fig 6.21).

FIG. 6.21

Turn the knurled head of the setting tool until the centre stem
of the tool is between the tolerance step on the tool head (Fig
6.22).

FIG. 6.22

Remove the setting tool and service spacer block, using the
adjuster manual override stem, wind back the tappet
assemblies

Refit the caliper as detailed in the caliper replacement

section.

26
Duco Reaction Beam Caliper
SECTION 7
Wear Sensor Gearbox Replacement
Remove the caliper assembly from the vehicle as detailed in
the caliper replacement section. Dismantle the caliper,
removing op-shaft, adjuster assembly and tappet assemblies
following the instructions provided in the relevant section.
Gearbox Fitment
Locate the new sensor gearbox into the housing and using
the Meritor service depth gauge/drift tool Part No. MBT1003,
(Fig 7.2) carefully tap the gearbox into position until the depth
gauge/drift tool abuts against the housing coverplate
mounting face (Fig 7.3).

Clean all components with a suitable Brake Cleaner and

inspect for signs of damage or excessive wear. If there is any
doubt in the suitability for further service replace with new
guaranteed components.

Gearbox Removal
NOTE: The Axial variant of this design of disc brake can be
fitted with sensor gearboxes which incorporate either a LH
thread, or RH thread, on the centre shaft. When
removing/reffitting gearboxes it is important to use the
correct Meritor tool Part No. MBT 1001.

Screw the appropriate LH/RH thread tool onto the gearbox FIG. 7.2 FIG. 7.3
centre shaft (Fig 7.1) and using the integral slide hammer
withdraw the old gearbox assembly. Sensor Gearbox Setting
When a new sensor gearbox is fitted it is important that the
following setting procedure is followed.

Initial Setting
Wind the sensor gear in the appropriate direction, LH or RH
thread, until the gearbox centre shaft is level with the inner
face of the gear (Fig 7.4).

IMPORTANT: Do not wind the gear too far, this will cause the
inner shaft to become dis-engaged from the sensor gear. If
this occurs the sensor gearbox must be removed and
replaced.

FIG. 7.1

Clean the gearbox aperture in the housing with a suitable

Brake Cleaner.

FIG. 7.4

27
Duco Reaction Beam Caliper
Re-assemble the caliper following the appropriate
instructions for tappet, op-shaft and adjuster replacement in
section 6.
Turn the knurled head of the setting tool until the centre
stem of the tool is between the tolerance step on the tool
head (Fig 7.7).

Final Setting
With the caliper correctly assembled it is necessary to
complete the gearbox setting procedure, before fitting the
wear sensor cable to the brake, where applicable, and the
brake to the vehicle.
Fit the Meritor service tool Part No. MBT 1003, setting spacer
block into the pad aperture and using the manual override
stem adjust the tappets out until they abut the setting spacer
(Fig 7.5).

FIG. 7.7

Remove the service setting tool and spacer block, wind back
the tappet assemblies using the override stem and refit the
caliper assembly following the caliper replacement section.

FIG. 7.5

IMPORTANT: Always de-adjust/adjust the brake carefully by

hand with a suitable spanner. Never exceed a maximum
torque of 40 Nm in either direction and NEVER use power
tools, air or electric, to de-adjust or adjust the brake.

Insert the Meritor service setting tool MTB 1003 through the
sensor aperture in the caliper housing and ensure it seats
correctly in the counterbore (Fig 7.6).

FIG. 7.6

28
Duco Reaction Beam Caliper
SECTION 8
Guide Sleeve, Dust Cover, Retainer &
Bush
Guide Sleeve, Dust Cover, Retainer & Bush Removal
Remove the caliper assembly as detailed in the caliper
replacement section. Transfer to a suitable workbench and
separate the housing assembly from the carrier as detailed in
the Housing replacement section. Place the housing
assembly, coverplate side against the bench surface, to
expose the guide sleeve areas. Withdraw the guide sleeves
and remove the guide sleeve dust covers from the housing.
IMPORTANT: Measure the length of the longer guide sleeve
before discarding (Fig 8.1). Record this measurement as it
will be required to confirm components when re-assembling.
FIG. 8.1
NOTE: the process of removing the guide sleeve bushes from
the housing will at the same time remove the dust cover
retainers which are pressed into the mouth of the housing
guide sleeve bores
MPORTANT: There are Radial and Axial alternative design
brakes available. Radial brakes use two plain bushes and two
oval brass bushes. Axial brakes use two plain bushes and one
oval brass bush. Irrespective of brake design always ensure
that the new bushes are fitted into the correct guide sleeve
bore.
FIG. 8.2a FIG. 8.2b
NOTE: Radial brakes are handed by the position of the plain
bushes. A milled slot or drill point on the housing guide sleeve
turret (Fig 8.2a & Fig 8.2b) is provided to identify the plain
bush guide sleeve bore.
It is important before the oval brass bushes are removed, to
mark precisely their position in the guide sleeve bore as
follows;
Position the housing with the coverplate uppermost, looking
into the appropriate guide sleeve bore observe the two
notches on the bush edge. Join the two notches with a rule or
straight edge and mark the housing turret (Fig 8.3).
FIG. 8.3
Using suitable drift tools press out the brass bush/bushes and
plain bushes together with the dust cover retainers.
Ensure the housing guide sleeve bores are not damaged.
Guide Sleeve, Dust Cover, Retainer & Bush Replacement
Clean the guide sleeve bores with a suitable Brake Cleaner or
clear methelayted spirits. Examine the condition of the bores
for wear, corrosion or damage. If there is any doubt in the
suitability for further service, replace with a new housing
assembly.
IMPORTANT: There are alternative design brakes and
components in service whch need to be identified before
begining re-assembly.
29
Duco Reaction Beam Caliper
Identification Procedure
Refer to the guide sleeve measurement recorded on removal
and ensure when re-assembling only the combination of
components detailed below are used.
Dust Cover Retainer
Place one of the new retainers in the mouth of the guide
sleeve bore - tappet side, and using the Meritor service tool
Part No. MBT 1000, shown (Fig 8.5)

a) Original guide sleeve length 100mm use;

Long sleeve 100mm, Long bolt 124mm, End caps 18mm

b) Original guide sleeve length 106mm use;

Long sleeve 106mm, Long bolt 130mm, End caps 23mm

IMPORTANT: Do not attempt to mix/use guide sleeves, bolts

or end caps which deviate from the combinations detailed
above.
FIG. 8.5
Look in to one of the guide sleeve bores in the caliper Carefully pull the retainer squarely into position until the
housing, turret side, and locate the machined chamfer. (Fig retainer shoulder abuts against the housing (Fig 8.6).
8.4).

CHAMFER

FIG. 8.6
FIG. 8.4
Fit the second retainer following the same procedure
Note: It may only be possible to observe the chamfer in the
shorter bore on certain installations.

Although not its primary function it is used to determine the

correct location of the top guide sleeve bush

30
Duco Reaction Beam Caliper
Brass Bush
Axial Brakes
Place the new bush on the housing and ensure the notches
on the bush edge align with the marks on the guide sleeve
turret (Fig 8.7).
FIG. 8.7
Using the Meritor service tool Part No. MBT 1000, pull the
bush into the guide sleeve bore (Fig 8.8).
FIG. 8.8
The correct position of the bush can be confirmed by
measuring the distance from the top edge of the bush to the
edge of the machined chamfer in the guide sleeve bore,
actuator side. This should be 0 - 2mm, (Fig 8.9).
FIG. 8.9
IMPORTANT: Do not apply excessive force when pulling the
bush into the housing as this may result in damage to the
bush or dust cover retainer.
Radial Brakes
Place one of the new brass bushes on the housing and ensure
the notches on the bush edge align with the marks on the
guide sleeve turret.( Fig 8.5).
Using the Meritor service tool Part No. MBT 1000, pull the
bush into the guide sleeve bore until it is a maximum 1mm
from the dust cover retainer (Fig 8.10).
FIG. 8.10
Place the second bush on to the housing again ensure the
notches on the bush edge align with the marks on the guide
sleeve turret (Fig 8.5).
Using the Meritor service tool Part No. MBT 1000, pull the
bush into the guide sleeve bore.
The correct position of the bush can be confirmed by
measuring the distance from the top edge of the first bush to
the bottom edge of the second bush. This should be 77mm
+/- 1mm, (Fig 8.11)
77mm ± 1mm
FIG. 8.11
31
Duco Reaction Beam Caliper
Plain Bushes
Axial & Radial Brakes
Place one of the new bushes on the housing, actuator side
with the internal chamfer uppermost, (Fig 8.12).
FIG. 8.12
Using the Meritor service tool Part No. MBT 1000, pull the
bush into the guide sleeve bore until it is a maximum of 1mm
from the dust cover retainer (Fig 8.13).
FIG. 8.13
Place the second bush on to the housing with the internal
chamfer towards the housing (Fig 8.14).
FIG. 8.14
Using the Meritor service tool Part No. MBT 1000, pull the
bush into the guide sleeve bore.
32
The correct position of the bush can be confirmed by
measuring the distance from the top edge of the first bush to
the bottom edge of the second bush. This should be 77mm
+/- 1mm, (Fig 8.15)
77mm ± 1mm
FIG. 8.15
IMPORTANT: Do not apply excessive force when pulling the
bush/s into the housing as this may result in damage to the
bush/s or dust cover retainer.
Guide Pin & Dust Cover Fitment
Lightly lubricate the new guide sleeves and the guide pin
dust covers, on the inside only, with the grease provided in
the service kit or specified by the vehicle manufacturer.
Note: Only use the grease supplied with replacement
components/kits or that specified by the vehicle
manufacturer. Under no circumstance should any other type
of grease be used.
Fit the new dust covers onto the housing ensuring the square
section bead locates correctly in the retaining grooves.
Fit the guide sleeves into the new caliper housing from the
actuator side (Fig 8.16).
FIG. 8.16
Duco Reaction Beam Caliper
Carefully push the guide sleeves through the dust covers (Fig NOTE: Take care not to damage the guide pin or tappet dust
8.17) ensuring the location of the dust covers on the housing covers when locating the carrier on the housing
are not disturbed.

Locate the guide pin dust covers on the carrier.

Carefully slide the carrier slightly to check the secure location
of the dust covers (Fig 8.20).

FIG. 8.17

Wipe off any excess grease from the end of the guide sleeve
(Fig 8.18). FIG. 8.20
Slide the carrier backwards and forwards several times to
check the smooth movement of the housing on the guide pins.
Fully tighten the guide pin bolts to a torque of 450 -500Nm.
NOTE: If a suitable fixture is not available to hold the caliper
securely the final tightening of the guide pin bolts to
450 - 500 Nm can be done when the brake assembly has been
re-fitted to the vehicle. Ensure there is sufficient access under
the vehicle to carry out the procedure, and fit the guide pin
caps, if this option is taken.
Check again the free movement of the housing assembly on
the guide pins.

FIG. 8.18 End Cap Fitment

Carefully lower the carrier into position on the housing
assembly and ensure the guide sleeves locate in the counter
bores machined in the carrier (Fig 8.19).
Using a copper faced mallet, carefully tap one of the new
guide pin caps into the housing until it retains itself.
Using a suitable size tool, or hexagon socket tap the cap into
the bore until it is flush with the top of the guide sleeve turret
(Fig 8.21).

FIG. 8.21
FIG. 8.19
Refit the caliper assembly as detailed in the Caliper
Fit the new guide pin bolts and torque to an initial torque of Replacement section.
50Nm only at this stage.

33
Duco Reaction Beam Caliper
Tightening Torques
SECTION 9 Guide Pin Bolt.................................................450 - 500Nm

Servicing
Adjuster Stem..........................................Maximum 40Nm
Although there is no routine maintenance of the caliper
required it is important the following inspections are carried
out at the periods specified, or those detailed in the vehicle
Pad Retaining Plate Bolt ...................................33 - 40Nm
manufacturers manual.

M8 Sensor/Switch Retaining Screw ................14 - 20Nm

Every 3 months or 20,000Km. M10 Sensor/Switch Retaining Screw ..............33 - 40Nm
A visual assessment of pad life remaining should be made.
Brake pads should be replaced when the lining thickness has
worn to 3mm. Cover Plate Bolt

Visually inspect the general condition of the brake assembly C. DUCO: 7 bolts M12 - tighten to 110 - 130Nm
for damage or corrosion. If there is any doubt in the suitability D. DUCO: 8 bolts M14 - tighten to 190 - 210Nm
for further service replace/rectify in accordance with the
vehicle manufacturers recommendations.

Every 12 months
Remove the road wheels and brake pads as described in the
pad replacement section.
Inspect the guide pin and tappet dust covers and ensure they
are undamaged and securely located. If any of the dust covers
are detached or damaged the relevant area of the brake
should be dismantled and the components examined for
corrosion or damage. Replace/rectify in accordance with the
vehicle manufacturers recommendations.
Check the housing assembly slides easily on the guide
sleeves secured to the carrier. If the housing does not slide
easily on the guide sleeves remove from the carrier as
described in the housing replacement section. Examine the
guide sleeves and bushed housing guide sleeve bores for
signs of corrosion or wear. If there is any doubt in the
suitability for further service replace with new components.

WARNING: Take care not to trap fingers whilst checking the

sliding action of the brake.

Check the brake disc for signs of heavy grooving, cracking or

corrosion and the thickness dimension is in accordance with
the vehicle manufacturers recommendations. Replace as
necessary.

Grease Specification
Fuchs Unitemp II
IMPORTANT: Only use the grease supplied with replacement
components/kits or that specified by the vehicle
manufacturer. Under no circumstance should any other type
of grease be used.

34
Duco Reaction Beam Caliper

SECTION 10
Service Tools
Bush & Retainer Tool Sensor Gearbox Removal Tool
(Guide Sleeve & Tappet)
Meritor Part No. MBT 1000 Meritor Part No. MBT 1001

FIG. 10.1 FIG. 10.3

Adjuster Setting Tool Setting Tool Kit

(Early level adjusters only) (Wear Sensor Gearbox)
Meritor Part No. MBT 1002 Meritor Part No. MBT 1003

FIG. 10.2 FIG. 10.4

35
World Headquarters
Troy, Michigan USA
www. meritorauto.com
For further information contact
Meritor HVS Limited
After Market Services
Park Lane, Great Alne, Alcester
Warwickshire B49 6HT
U.K.
Telephone: +44 (0)845 6067733
Fax: +44 (0)845 6068844
© Copyright 2000
Meritor Automotive
All rights Reserved
Publication 4.90.1
Meritor Heavy Vehicle Braking
Systems (UK) Limited
Grange Road
Cwmbran NP44 3XU
U.K.
Telephone: +44 (0)1633 834294
Fax: +44 (0)1633 834191
Descriptions and specifications
were in effect at the time of
publication and are subject to
change without notice or
liability. Meritor reserve the
right to make design
improvements, change or
discontinue parts at any time.