22E081 – Loose Brake Pad Retaining Clip May Damage Tire – Haldex ModulT Gen II Air Disc Brake

September 27, 2022 NHTSA CAMPAIGN NUMBER: 22E081000

Loose Brake Pad Retaining Clip May Damage Tire

A retaining clip or bracket that detaches can become a road hazard, increasing the risk of a crash.

 

NHTSA Campaign Number: 22E081

Manufacturer Haldex Commercial Vehicle Systems

Components 

 

Summary

Haldex Commercial Vehicle Systems (Haldex) is recalling certain ModulT Gen II Air Disc Brake. The retaining clip in the brake pad retaining assembly may be loose or could detach, loosening the brake pad.

 

Remedy

Dealers will inspect and repair the spring bracket assembly as necessary, free of charge. Owner notification letters were mailed October 12, 2022. Owners may contact Haldex customer service at 1-800-752-2501.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.

 


Please be reminded of the following requirements:

You are required to submit a draft owner notification letter to this office no less than five days prior to mailing it to the customers. Also, copies of all notices, bulletins, dealer notifications, and other communications that relate to this recall, including a copy of the final owner notification letter and any subsequent owner follow-up notification letter(s), are required to be submitted to this office no later than 5 days after they are originally sent (if they are sent to more than one manufacturer, distributor, dealer, or purchaser/owner).

Please be reminded that under 49 U.S.C. § 30112(a)(3), it is illegal for a manufacturer, to sell, offer for sale, import, or introduce or deliver into interstate commerce, a motor vehicle or item of motor vehicle equipment that contains a safety defect once the manufacturer has notified NHTSA about that safety defect. This prohibition does not apply once the motor vehicle or motor vehicle equipment has been remedied according to the manufacturer’s instructions.

 


ModulT Gen2 ADB Caliper Pad Retainer and Spring Bracket Inspection and Repair.

 

Overview:

  • This work instruction demonstrates how to inspect and repair the pad retainer spring bracket to ensure proper installation.
  • This inspection can be performed with the wheel on.
  • These instructions demonstrate inspecting both Super Single and Dual tire configurations.
  • In the event the pad retainer is missing, tire removal may be required to repair the spring bracket and pad retainer.

For Support Contact Haldex Technical Services at:
Phone 800-643-2374 / 816-891-2470
TechServices.KansasCity@haldex.com

 

Contents:

1. Fault description

2. Inspection procedure on super single tires

3. Inspection procedure from outside the trailer on dual tire configuration

4. Inspection procedure from under the trailer on dual tire configuration

5. Reference

6. Repair procedure

7. Actions if there are missing or damaged components 8. Contact information

 

Fault Description

The spring bracket (1) may be trapped under the pad retainer (2).

This photo shows the spring bracket (1)
trapped under the pad retainer (2)

 

Super Single Spring Bracket Inspection

  • The spring bracket is easily visible and physically accessible under the trailer.
  • Ensure the clip fully extends through the pad retainer bar slot. There should be a full opening at the top of the spring bracket.

 

Dual Tire Spring Bracket Inspection: Outside the Trailer

Dual Tires:

There are two methods to inspect the spring bracket: Either Outside the trailer, or under the trailer.

Outside the trailer, facing the rim:

1. Look through the rim holes to ensure the spring bracket fully exceeds the pad retainer.

2. You may need to rotate the wheel to align a rim hole and caliper.

3. You can also utilize a bore scope to view these components.

4. There should be a full opening at the top of the bracket.

Pictured as seen through the rim face.

 

Dual Tire Spring Bracket Inspection: Under the Trailer

Dual Tires, Under the Trailer:

1. Use a borescope to look through the back of the rim to ensure the spring bracket fully exceeds the pad retainer.

2. There should be a full opening at the top of the spring bracket.

Pictured as seen with a borescope from behind the wheel, under the trailer.

 

Repair Procedure

1. If the spring bracket is not fully extended, you may need to remove the wheel assembly to access the bracket. Use appropriate tire removal and safety procedures compliant with your organization and tire removal instruction.

2. Use your fingers or a screwdriver to shift the pad retainer until the spring seats into the proper location.

 

Actions if there are missing or damaged components

If during the inspection you find any missing or damaged ADB components related to this matter:

1. Place the Vehicle Out of Service.

2. For replacement, Perform the procedure shown in the next several pages.

3. Replace any other components that were damaged as a result of this situation.

4. Process a warranty claim in accordance with the attached warranty policy or your organization’s warranty policy.

 

Replacement instructions and more can be found in Haldex Installation Guide L30051. Please download this manual from Web Address of Service Manual:

https://www.haldex.com/globalassets/north-america/documents/air-disc-brakes/l30051.pdf

https://static.oemdtc.com/Recall/l30051.pdf

l30051

For Support Contact Haldex Technical Services at:
Phone 800-643-2374 / 816-891-2470
TechServices.KansasCity@haldex.com

 

Caliper Replacement Procedure

Step 1: Tire Removal

Warning

Personal safety equipment must be worn when working with equipment.

Lift up and support the vehicle axle to remove the tire / wheel assembly in accordance with the axle or vehicle recommendations.

1. On a flat even surface, block the wheels

2. Lift the axles and place on jack stands.

3. Release the parking brake.

4. Check for free rolling resistance of the tire / wheel assembly. If the resistance is higher than expected, tap the tire to remove the rest tension. If the wheel still does not rotate freely then further inspection is needed.

5. Remove the lug nuts.

6. Remove the tire / wheel assembly

 

Step 2: Brake Pad Removal

1. Using a T55 Torx, manually turn the reset shaft counterclockwise to de-adjust the brake so that the thrust plate fully retracts to its inner position.

2. An audible clicking sound will be felt and heard when de-adjusting. The stop of the fully retracted inner thrust plate position must be distinct, but do not exceed 15 ft-lbs. (20Nm) in torque or leave it tightened in this position.

3. Remove the pad retainer (B) by first pushing and holding down the spring bracket (A), while the spring bracket is held down, slide in and remove the pad retainer. A tool can be used to help slide in the pad retainer if unable to remove by hand.

4. Remove the two pad springs (C).

5. Remove the brake pads. Always remove the outer brake pad first (D), followed by the inner brake pad (E). a. The inner brake pad back plate locates on two holes which mate to the thrust plate, therefore the pad cannot be removed with the outer pad still being in place. Once the outer pad is removed, the caliper can be slid laterally to allow for the inner pad removal (E).

6. Remove the pad retainer spring bracket (A)

 

Step 3: Brake Chamber Removal

1. Carefully clean around the mating surfaces of the brake chamber (A) and the caliper (B) to ensure that dirt does not get into the mechanism area when removing the brake chamber.

2. If applicable, ensure that the spring brake chamber (F) is fully disengaged and mechanically secured in the released position.

3. Ensure that the brake chamber (A) is depressurized.

4. Mark and remove the hose connections of the service brake (C) and if applicable the parking brake (D).

5. Remove the two nuts (E) holding the brake chamber. Remove the brake chamber (A) from the caliper (B)

 

Step 4: Caliper Removal

1. Loosen bolts with long wrench, one at a time, ensuring top bolt is still supporting caliper.

2. Confirm the caliper is supported.

3. Remove the bolts completely.

 

Step 5: Caliper Installation

Never reuse bolts

1. Starting with top bolt, re-install the caliper onto the brake spider using proper bolts for the specific carrier design. Never reuse bolts and check for proper length.

Refer to the next page for bolt kit numbers. Too long of bolt can  bottom out on Rotor.

a. Pre-torque bolts using clocking numbers and recommended pre-torque setting for size of bolts. Refer to Table 1 on page 12.

b. Verify the pre-torque of the bolts a second time, and if necessary, re-tighten to recommended settings, Table 1, page 12

c. For final Torque specifications refer to Table1, page 12, Carrier bolt section. Care most be taken to match size of bolt and whether dry or lubricated for proper torque.

 

Bolt Kit Part Numbers

790-22060 Bolt Kit M20X55mm 790-22062 Bolt Kit M16X55mm 790-22063 Bolt Kit M20X60mm 790-22067 Bolt Kit M16X60mm

790-22068 Bolt Kit M16X60mm 790-22069 Bolt Kit M18X55mm

 

Tightening Torques

Brake chamber fixation nuts. 130 ft-lbs ± 22 ft-lbs (180 ± 30 Nm)

Carrier bolt(s).331 ft-lbs ± 22 ft-lbs (450 ± 30 Nm

 

Step 6: Chamber Installation

1. Ensure the brake chamber being installed is the correct one for the application and vehicle. If a spring brake chamber is being installed, ensure that the parking brake spring is caged in accordance with the manufacturer’s instructions.

2. Ensure the surface of the caliper that mates with the brake chamber is free from dirt, moisture and corrosion. Do the same check on the brake chambers mating face (A) and seal. Ensure the brake chamber seal is in the correct position and not damaged.

3. Apply a small amount of general-purpose grease in the ball cup of the brake chamber lever. Do not overfill the cup or let grease fall inside the brake.

4. Fit the new brake chamber (A) to the caliper (B) with nuts (E). Screw the nuts home first before torque tightening to ensure the brake chamber seats parallel.

5. Brake chamber fixation nut tightening torque is 130 ft-lbs. ± 15 ft-lbs. (180 ± 20 Nm). Follow the vehicle/axle manufacturers recommendations.

6. Fit the brake chamber hose connection of the service brake (C) and if applicable the parking brake (D). If fitting both hoses, ensure connections (C) and (D) are the correct way around.

7. Remove the ventilation drain plug that faces downwards from the service brake housing and if applicable, also from the spring brake housing.

8. If applicable, release the parking brake and disengage the spring brake chamber’s caging mechanism so that the spring is released. Minimum 90 psi (6 bar).

9. With the service brake engaged and, where applicable, with the parking brake released, check the brake chambers, hoses and connections for leaks or damage

 

Step 7: Pad Installation

1. Ensure the brake caliper is fully de-adjusted before installing new brake pads.

2. Check all contact surfaces on the carrier, caliper, and thrust plate are free from dirt and corrosion. a. Clean if necessary.

3. Check abutment area on carrier for deep grooves, cracks, or deformation.

a. Replace carrier if grooves exceed 3mm or has cracks and deformation.

4. Install the inner brake pad into the caliper. a. Note: The inner brake pad locates onto the thrust plate on two points.

5. Install the outer brake pad into the caliper. a. Note: Ensure the friction material faces the rotor.

6. Install the new spring bracket into the caliper and ensure it is seated in the correct position.

7. Install the new pad springs and the pad retainer. a. Note: The pad retainer is fitted by first locating the pad retainer in the housing end in the caliper aperture, then compressing the pad springs and locating the pad retainer slot over the caliper latch, and finally sliding the pad retainer under the caliper latch until the spring bracket pops into its locking position. If necessary, use a tool to help push the pad retainer into position.

8. Using a T55 Torx, manually adjust the brake by turning the reset shaft clockwise until the pads touch the rotor and you feel an end stop.

9. Then turn the reset shaft counterclockwise 2 clicks. a. This procedure sets the initial brake pad clearance.

10. Fit the reset shaft protective plug into the caliper, ensure it is correctly orientated and pushed fully into its correct sealing position.

Failure to do so may compromise the life of the brake.

 

Step 8:  Tire Installation

Mounting

IMPORTANT! Make sure that the brake hoses are in good condition, that they are layed/ducted and fastened correctly.

1. Check the free rolling resistance. The disc brake must not be obstructed in any way.

2. Mount the wheel.

IMPORTANT! If the disc brake is equipped with a parking brake actuator, ensure that the brake system is pressurized, and the spring brake chamber is fully engaged and mechanically secured in the active position. See the vehicle manufacturer’s instructions.

IMPORTANT! Apply air to the parking brake. Make sure that there is sufficient air in the system (min. 6 bar).

 

Lowering of the vehicle axle

1. Activate the parking brake if fitted with a spring brake chamber.

2. Lift the axles so that the stands can be removed.

3. Carefully lower the vehicle to the ground.

4. Remove the wheel blocks

 

Haldex Technical Support

For Support Contact Haldex Technical Services at:

Phone 800-643-2374 / 816-891-2470

TechServices.KansasCity@haldex.com

Or

Contact your Haldex Sales Representative

 


Chronology :

On Sept. 13, 2022 an OEM trailer manufacturer; a purchaser of axles from a Haldex axle customer, reported an on-road incident that appeared to involve the subject component. The incident appeared to involve the retaining clip installation described above.

On Sept. 15, 2022 a second incident was reported that appeared unrelated based on the initial information received. The axle manufacturer also provided photographs of apparent clip misalignment on un-installed units and reported that eight brake assemblies from incoming inventory appeared misaligned. Haldex immediately began investigating the issue and implemented containment actions in their manufacturing plant, including suspending brake shipments on Sept. 15, 2022.

On Sept. 19, 2022 Haldex began sending inspection teams to the trailer manufacturer locations and several trailer manufacturer customer locations to inspect assemblies. Haldex has inspected approximately 3800 units to date and confirmed 8 with misaligned brake spring retaining clips. Haldex also sent inspection teams to the axle manufacturing facility to inspect and contain any improperly assembled products. Haldex confirmed that even with a loose brake pad, overall braking function on the trailer was still effective.

On Sept. 21, 2022 Haldex confirmed that the second incident reported by the trailer manufacturer did in fact involve an improperly assembled brake retaining clip. This was confirmed by onsite inspection of the subject trailer showing that the brake retaining clip and retainer bar were missing. Haldex’s investigation indicated that even though overall trailer braking function was minimally impacted, a loose retainer bar or retaining clip could hit other vehicle components, and may result in the retaining clip or retainer bar hitting the roadway and creating a road hazard.

On Sept. 21, 2022, Haldex determined that an unreasonable risk to motor vehicle safety resulting from the improperly assembled clip could not be ruled out.

 


1 Affected Product

Equipment

BRAND PART NO. PRODUCTION DATES
HALDEX GEN II AIR DISC BRAKE

 


5 Associated Documents

Recall 573 Report

RCLRPT-22E081-9542.PDF 215.337KB

RCLRPT-22E081-9542

 


Recall Acknowledgement

RCAK-22E081-8937.pdf 682.618KB

RCAK-22E081-8937

 


Remedy Instructions and TSB

RCRIT-22E081-5095.pdf 1497.196KB

RCRIT-22E081-5095

 


Remedy Instructions and TSB

RCRIT-22E081-8755.pdf 4004.844KB

RCRIT-22E081-8755

 


ISSUED Owner Notification Letter(Part 577)

RCONL-22E081-5387.pdf 134.401KB

RCONL-22E081-5387

 


Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=22E081&docType=RCL

 


 

Bestseller No. 1
Bosch BSD812 SevereDuty 812 Severe Duty Disc Brake Pad
  • Bosch Severe Duty Semi-Metallic brake pads use the latest technology in friction for best in class performance, quiet operation, and long life
  • Severe Duty pads are made for vehicles subject to constant stop-and-go operation or that carry heavy payloads
  • OE-style multilayer shims, slots, and chamfers (where specified)
  • Engineered, tested, and manufactured in North America
  • Set includes pads for 1 axle (2 wheels), synthetic lube, and hardware (as applicable); pads come boxed with a paper inner wrap for added protection
Bestseller No. 2
Wagner Brake SevereDuty SX757 Disc Brake Pad Set
  • BUILT TOUGH -- Engineered for fleets and vehicles driven in demanding conditions
  • LONG LIFE -- Semi-metallic carbon-based friction material engineered in-house to deliver long lasting braking performance for the toughest applications
  • TESTED AND VALIDATED -- Rigorous OE-style on-vehicle testing to ensure optimal braking performance for vehicles under extreme heat, frequent stopping and heavy loads
  • OE DESIGN -- Features OE style shims, slots and chamfers
  • HARDWARE INCLUDED -- Premium stainless-steel hardware kits included for key applications
SaleBestseller No. 3
Wagner Brake SevereDuty SX1399 Disc Brake Pad Set
  • BUILT TOUGH -- Engineered for fleets and vehicles driven in demanding conditions
  • LONG LIFE -- Semi-metallic carbon-based friction material engineered in-house to deliver long lasting braking performance for the toughest applications
  • TESTED AND VALIDATED -- Rigorous OE-style on-vehicle testing to ensure optimal braking performance for vehicles under extreme heat, frequent stopping and heavy loads
  • OE DESIGN -- Features OE style shims, slots and chamfers
  • HARDWARE INCLUDED -- Premium stainless-steel hardware kits included for key applications
SaleBestseller No. 4
Bosch Automotive BSD802 SevereDuty 802 Severe Duty Disc Brake Pad
  • Bosch Severe Duty Semi-Metallic brake pads use the latest technology in friction for best in class performance, quiet operation, and long life
  • Severe Duty pads are made for vehicles subject to constant stop-and-go operation or that carry heavy payloads
  • OE-style multilayer shims, slots, and chamfers (where specified)
  • Engineered, tested, and manufactured in North America
  • Set includes pads for 1 axle (2 wheels), synthetic lube, and hardware (as applicable); pads come boxed with a paper inner wrap for added protection
Bestseller No. 5
Power Stop Z36-1363 Front Z36 Truck and Tow Brake Pads
  • The Carbon-fiber ceramic brake pad not only features thermal scorched pad surface for a fast break-in but chamfered slots for noise-free braking
  • The Carbon-fiber ceramic brake pads are chamfered and slotted and have premium stainless steel shims to ensure noise-free braking, just like the stock brake pads
  • An upgraded with powder coated backing plate perfect for muscle cars, significantly enhances braking performance and extends life by resisting rust and corrosion
  • Z36 Carbon-fiber brake pad set includes brake grease and premium stainless steel hardware kit. Before installing the rotor, clean it with mild soap and water. Then, wipe it clean with a lint-free cloth
  • CONFIRM FITMENT with the Product Description below!
Bestseller No. 6
Wagner Brake SevereDuty SX785 Disc Brake Pad Set
  • BUILT TOUGH -- Engineered for fleets and vehicles driven in demanding conditions
  • LONG LIFE -- Semi-metallic carbon-based friction material engineered in-house to deliver long lasting braking performance for the toughest applications
  • TESTED AND VALIDATED -- Rigorous OE-style on-vehicle testing to ensure optimal braking performance for vehicles under extreme heat, frequent stopping and heavy loads
  • OE DESIGN -- Features OE style shims, slots and chamfers
  • HARDWARE INCLUDED -- Premium stainless-steel hardware kits included for key applications
Bestseller No. 7
Bosch Automotive BSD1680 SevereDuty 1680 Severe Duty Disc Brake Pad
  • Bosch Severe Duty Semi-Metallic brake pads use the latest technology in friction for best in class performance, quiet operation, and long life
  • Severe Duty pads are made for vehicles subject to constant stop-and-go operation or that carry heavy payloads
  • OE-style multilayer shims, slots, and chamfers where specified
  • Engineered, tested, and manufactured in North America
  • Set includes pads for 1 axle 2 wheels, synthetic lube, and hardware as applicable; pads come boxed with a paper inner wrap for added protection
Bestseller No. 8
Wagner Brake SevereDuty SX967A Disc Brake Pad Set
  • BUILT TOUGH -- Engineered for fleets and vehicles driven in demanding conditions
  • LONG LIFE -- Semi-metallic carbon-based friction material engineered in-house to deliver long lasting braking performance for the toughest applications
  • TESTED AND VALIDATED -- Rigorous OE-style on-vehicle testing to ensure optimal braking performance for vehicles under extreme heat, frequent stopping and heavy loads
  • OE DESIGN -- Features OE style shims, slots and chamfers
  • HARDWARE INCLUDED -- Premium stainless-steel hardware kits included for key applications
Bestseller No. 9
Power Stop Front Z36-1680 Carbon-Fiber Ceramic Brake Pads Truck and Tow Z36
  • Z36 Truck and Tow brake pads have superior stopping power that is demanded by those who tow and haul, as well as the off-road enthusiast
  • To avoid exceeding the limits of your stock brakes, we recommend using Z36 pads any time you add weight to a vehicle by hauling a load, towing a trailer, or simply adding a larger wheel/tire combination
  • They are made from premium stainless-steel shims, which provide better heat dissipation & virtually noise-free braking
  • Includes premium stainless-steel hardware for hassle free installation
  • This product is compatible with:

    Ford F-250 Super Duty Pickup - 2013 - 2015 - 2WD And 4WD Models

    Ford F-350 Super Duty Pickup - 2013 - 2014 - 2WD And 4WD Models

    Ford F-450 Super Duty Pickup - 2013 - 2014

SaleBestseller No. 10
ACDelco Silver 14D369MX Semi-Metallic Front Disc Brake Pad Set
  • Ceramic, Semi-Metallic, and Organic formulas provide safety and reliability for a range of vehicle applications
  • Basic shims, slots, and chamfers help to diminish noise, vibration, and braking harshness
  • No curing or machining required, ready to be installed right out of the box
  • Some ACDelco Silver parts may have formerly appeared as ACDelco Advantage
  • Economical value with dependable quality

Last update on 2022-11-14 / Affiliate links / Images from Amazon Product Advertising API

This product was presentation was made with AAWP plugin.

 


 

 

Leave a Comment