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

SEOCONTENT-START

ModulT® Gen II Air Disc Brake Safety Recall Notice
Inspection and Repair Procedures ModulT Gen II ADB Caliper Pad
Retainer and Spring Bracket
Inspection and Repair Instructions Super Single Spring Bracket Inspection
• The spring bracket is easily visible and physically accessible Figure 2. 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
• Tire removal may be required to repair the spring bracket.
• These instructions demonstrate inspecting both the super single and Dual tire configurations.
Contents
1. Fault Description
2. Inspection Procedure on super single tires
3. Inspection Procedure on dual tire configuration from outside the trailer
4. Inspection Procedure on dual tire configuration from under the trailer
5. Repair Procedure
6. Actions to take if there are missing or damaged components
7. Contact information
Fault Description
The spring bracket may be trapped under the pad retainer.
Refer to Fig. 1 This photo shows the spring bracket (1a) trapped under the pad retainer (1b). Figure 1.
Spring bracket trapped under pad retainer 1a
1b under the trailer. Refer to Fig. 2
• 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
There are two methods to inspect the spring bracket: either outside the trailer, or under the trailer.
Outside the Trailer, Facing the Rim
Refer to Fig. 3
• Look through the rim holes to ensure the spring bracket fully exceeds the pad retainer.
• You may need to rotate the wheel to align a rim hole and caliper.
• You can also utilize a bore scope to view these components.
• There should be a full opening at the top of the bracket.
Under the Trailer
Refer to Fig. 4
• Use a borescope to look through the back of the rim to ensure the spring bracket fully exceeds the pad retainer.
• There should be a full opening at the top of the spring bracket. Figure 3. Figure 4. For technical support, call Haldex Technical Services at 800-643-2374 or 816-891-2470, email TechServices.KansasCity@haldex.com or contact your Haldex sales professional. For technical support, call Haldex Technical Services at 800-643-2374 or 816-891-2470, email TechServices.KansasCity@haldex.com or contact your Haldex sales professional. Repair Procedure WARNING Personal safety equipment must be worn when working Figure 5.
5a Caliper Replacement Procedure
Step 1. Tire Removal
Personal safety equipment with equipment.
• If the spring bracket is not fully extended, you may need WARNING must be worn when working with equipment. to remove the wheel assembly to access the bracket
• Use appropriate tire removal and safety procedures compliant with your organization and tire removal instruction
• Refer to Fig.5 Use your fingers or a screwdriver to shift the pad retainer until the spring seats in the proper position Actions to Take if There are Missing or Damaged Components
If during the inspection you find any missing or damaged ADB components related to this matter:
• Place the vehicle Out of Service
• Replace the caliper by performing the procedure shown in Haldex Installation Guide L30051
• Replace any other components that were damaged as a result of this situation
• 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. You may download this manual from https://www.haldex.com/globalassets/north-america/ documents/air-disc-brakes/L30051.pdf Contact Information
For technical support, call Haldex Technical Services at 800-643-2374 or 816-891-2470, email
TechServices.KansasCity@haldex.com or contact your Haldex Sales Representative. Top of spring bracket is trapped beneath edge of pad retainer bar. 5b Move pad retainer bar back and forth with fingers or a screwdriver – 5c – until spring bracket pops up into its correctly seated position 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. Blocking the wheels. Release parking brake. Remove tire / wheel assembly. For technical support, call Haldex Technical Services at 800-643-2374 or 816-891-2470, email TechServices.KansasCity@haldex.com or contact your Haldex sales professional. For technical support, call Haldex Technical Services at 800-643-2374 or 816-891-2470, email TechServices.KansasCity@haldex.com or contact your Haldex sales professional. Caliper Replacement Procedure
Step 2. Brake Pad Removal
Personal safety equipment Caliper Replacement Procedure B
Step 3. Brake Chamber Removal
A
Personal safety equipment WARNING must be worn when working with equipment. WARNING must be worn when working with equipment. IMPORTANT!
Always remove the outer brake pad first. Always install the inner brake pad first.
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.
a. 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.
2. 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.
3. Remove the two pad springs (C).
4. 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).
5. Remove the pad retainer spring bracket (A). C Remove pad retainer and pad springs. 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). C Clean mating surfaces of brake and chamber. Secure brake chamber in the released position. F E A
D
Remove brake pads. D A
E Remove brake chamber items.
B For technical support, call Haldex Technical Services at 800-643-2374 or 816-891-2470, email TechServices.KansasCity@haldex.com or contact your Haldex sales professional. For technical support, call Haldex Technical Services at 800-643-2374 or 816-891-2470, email TechServices.KansasCity@haldex.com or contact your Haldex sales professional. Caliper Replacement Procedure
Step 4. Caliper Removal
Personal safety equipment Caliper Replacement Procedure
Bolt Kit Part Numbers
790-22060 Bolt Kit M20X55mm 790-22062 Bolt Kit M16X55mm WARNING must be worn when working with equipment. 790-22063 Bolt Kit M20X60mm 790-22067 Bolt Kit M16X60mm 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. Always 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) CAUTION check bolts for proper length. Bolts that are too long can Torque Tightening bottom out on the rotor. Refer to next page for bolt kit numbers.
1. Starting with top bolt, re-install the caliper onto the brake spider using proper bolts for the specific carrier design.
a. Pre-torque bolts using clocking numbers and 3 4 2
recommended pre-torque setting for size of bolts. ⁵ 6 Screw Thread
M20x2.5 M16x1.5 Offset (mm)
56
55 Pre-Torque
N-m FT-LBS 200 145
95 70 (Dry)
N-m FT-LBS 675±34 500 ±25
350±34 255±25 (Lubricated)
N-m FT-LBS 530±34 390±25
275±34 200±25 Refer to Table 1 on page 12. Bolt tightening sequence M18x1.5 65 120 88 450±30 331±22 350±30 258±22 b. Verify the pre-torque of the bolts a second time, SHOULDER BOLT Torque Plates 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 must be taken to match size of bolt and whether dry or lubricated for proper torque. BRAKE SPIDER OUTER CALIPER BOLT INNER CALIPER BOLTS BRAKE CALIPER Width (Inches)
1
1.225 Screw Length (mm)
55
60 Washer Thickness (mm)
3.5 ±0.5
3.5 ±0.6 SHOULDER BOLT IN OUTER MOUNTING HOLE
SHORT GUIDE PIN LONG GUIDE PIN For technical support, call Haldex Technical Services at 800-643-2374 or 816-891-2470, email TechServices.KansasCity@haldex.com or contact your Haldex sales professional. For technical support, call Haldex Technical Services at 800-643-2374 or 816-891-2470, email TechServices.KansasCity@haldex.com or contact your Haldex sales professional. Caliper Replacement Procedure
Step 6. Brake Chamber Installation
Personal safety equipment Caliper Replacement Procedure
Step 7. Pad Installation
Personal safety equipment 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.
Note: The pad retainer is fitted by first locating the pad WARNING must be worn when working with equipment. WARNING must be worn when working with equipment. retainer in the housing end in the caliper aperture, then compressing the pad springs and locating the pad retainer 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 Place a small amount of general purpose grease in the ball cup of the brake chamber lever. F 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. Clean if necessary.
3. Check abutment area on carrier for deep grooves, cracks, or deformation. Replace carrier if grooves exceed 3mm or has cracks and deformation.
4. Install the inner brake pad into the caliper.
Note: The inner brake pad locates onto the thrust plate on two points.
5. Install the outer brake pad into the caliper.
Note: Ensure the friction material faces the rotor. 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.
Note: 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. 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 D A
manufacturers recommendations. E IMPORTANT!
Always install the inner brake pad first. IMPORTANT!
Ensure that friction material faces the rotor. IMPORTANT!
Use new parts in pad kit. Do not reuse old parts. 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. Fit the chamber to the caliper
with nuts and tighten. B
Fit hose connections. Remove ventilation drain plugs from bottom
side of spring brake chamber. B A C Replace brake pads. OK OK Install new pad springs and pad retainer For technical support, call Haldex Technical Services at 800-643-2374 or 816-891-2470, email TechServices.KansasCity@haldex.com or contact your Haldex sales professional. For technical support, call Haldex Technical Services at 800-643-2374 or 816-891-2470, email TechServices.KansasCity@haldex.com or contact your Haldex sales professional. L56070
P10/22 2. M ALP
Printed in the USA
United States 816-891-2470
Canada 519-621-6722
Mexico 52-81-81569500
To learn more, contact your Haldex sales professional or visit haldex.com
Caliper Replacement Procedure
Step 8. Tire Installation
WARNING
Personal safety equipment must be worn when working with equipment.
Mounting of the Wheel
IMPORTANT! Make sure that the brake hoses are in good condition, that they are laid/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. Remove the stops.
Secure spring brake in the active position.
Mount the wheel.
For technical support, call Haldex Technical Services at 800-643-2374 or 816-891-2470, email TechServices.KansasCity@haldex.com or contact your Haldex sales professional.

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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 ModulT Gen2 ADB Caliper Pad Retainer and
Spring Bracket Inspection and Repair.
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
2 under the pad retainer (2). 1 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: Pictured as seen through the rim face. 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. 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 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 Caliper Replacement Procedure
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. a. 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. 2. 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. 3. Remove the two pad springs (C). 4. 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). 5. Remove the pad retainer spring bracket (A) Caliper Replacement Procedure
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) Caliper Replacement Procedure
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. Caliper Replacement Procedure
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. Caliper Replacement Procedure
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 Caliper Replacement Procedure
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. Caliper Replacement Procedure
Step 6: Chamber Installation (continued) 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 Caliper Replacement Procedure
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. Caliper Replacement Procedure
Step 7: Pad Installation (continued)
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. Caliper Replacement Procedure
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. 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. 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

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L56069
P10/22 2. M ALP
Printed in the USA
Haldex Brake Products Corporation 10930 North Pomona Avenue Kansas City, MO 64153-1256
Phone: (816) 891-2470
Fax: (816) 891-9947
haldex.com
September 29, 2022
Dear Customer:
This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act.
Haldex has determined that an assembly defect relating to motor vehicle safety exists in certain Haldex ModulT Gen II air disc brakes (ADB).
The brake pad retaining assembly on a very small percentage of Haldex ModulT Gen II air disc brakes (ADB) produced in Monterrey, MX, between February 11, 2021, and September 16, 2022, may contain an improperly installed retaining clip.
An improperly installed spring bracket may enable the pad retainer and spring bracket to detach from the brake and allow the brake pad to loosen. A loose brake pad may reduce brake effectiveness and may cut a tire valve resulting in a flat tire,
and eventually cause damage to the brake pad or wheel. A detached spring bracket or pad retainer may come in contact with other vehicle parts or fall into the roadway, creating road debris and a potential traffic hazard increasing the risk of a crash.
Haldex will remedy the defect without charge. To remedy, the brake(s) need to be inspected by a trained technician and, if necessary, repaired. The inspection involves a visual check to determine whether the spring bracket is properly seated.
Repair, if needed, involves adjusting the pad retainer slightly to allow the spring bracket to seat properly. Inspection and repair are relatively simple and are conducted without removing the wheel or lifting the vehicle, with minimal impact to service.
This repair takes approximately 5 minutes per brake to perform. This repair will be done free of charge. The remedy is available immediately.
Please contact a Haldex representative at 1-800-643-2374 at your earliest convenience to arrange an inspection, repair, or training, if required. Instructions on performing the inspection and repair (if necessary), and the procedure and forms for submitting reimbursement claims for repair costs are attached to this notification.
You may submit a complaint to the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Ave., SE., Washington, DC 20590; or call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY: 1-800-424-9153); or go to http://www.safercar.gov, if you believe that:
(A) The manufacturer, distributor, or dealer has failed or is unable to remedy the defect without charge.
(B) The manufacturer has failed or is unable to remedy the defect without charge within a reasonable time, which is not longer than 60 days after the owner’s first tender to obtain repair following the earliest repair date specified above.
Regards,
Bill Hays
VP of Quality, Warranty and Technical Services
IMPORTANT SAFETY RECALL
NHTSA Recall No. 22E-081

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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 22E-081
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Haldex Commercial Vehicle Systems SEP 27, 2022 NHTSA Recall No. : 22E-081 Manufacturer Recall No. : NR Manufacturer Information :
Manufacturer Name : Haldex Commercial Vehicle Systems Address : 10930 North Pomona Avenue
Kansas City MO 64153
Company phone : 816-801-2335 Population :
Number of potentially involved : NR Estimated percentage with defect : NR Equipment Information : Brand / Trade 1 :
Model : Haldex Brake Product Corp ModulT Gen II Air Disc Brake Part No. : ModulT GenII ADB Size : NR Function : NR
Descriptive Information : The recall population includes all brakes of this model manufactured at the Haldex Monterrey Facility starting with initial production 2/11/21 and ending when containment was implemented on 9/15/22
Production Dates : FEB 11, 2021 – SEP 14, 2022
Description of Defect :
Description of the Defect : The brake pad retaining assembly on certain Haldex air disc brakes (ADB) may contain an improperly installed retaining clip. If the retaining clip is improperly installed, the retainer bar may move and fail to retain the brake pads fully within the brake assembly, especially under road vibration conditions. Brake pads do not detach from the brake assembly but a loose brake pad, retainer bar, or retaining clip may come in contact with other nearby wheel components, and the retaining clip or retainer bar may fall into the road.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : Under certain road use conditions, an improperly installed retaining clip may enable the retainer bar and retaining clip to detach from the brake and may allow the brake pad to loosen. A loose brake pad may slightly reduce brake effectiveness, and may cut a tire valve resulting in a flat tire, and eventually
can cause damage to the brake pad or wheel. A detached retaining clip or Part 573 Safety Recall Report 22E-081 Page 2 retainer bar may come in contact with other vehicle parts and may fall into the roadway, creating road debris and a potential traffic hazard.
Description of the Cause : An incomplete manual assembly process resulted in inconsistent installation of the retaining clip and brake pad retainer bar. Identification of Any Warning NR
that can Occur : Involved Components : Component Name : NR Component Description : NR Component Part Number : NR Component Name : NR Component Description : NR Component Part Number : NR Supplier Identification : Component Manufacturer
Name : Haldex Brake Products Address : 10930 N. Pomona Avenue
Kansas City Missouri 64154
Country : United States 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 The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 22E-081 Page 3 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. Description of Remedy :
Description of Remedy Program : Haldex, their representative(s), or other trained technicians will inspect
and, if necessary, repair the improperly assembled spring bracket assembly. How Remedy Component Differs from Recalled Component : Identify How/When Recall Condition was Corrected in Production : A remedied component has the retainer bar fully seated in the notch with the retaining clip fully protruding through the retaining clip window on the retainer bar.
Haldex has identified the assembly plant at which the subject ADBs were produced and has implemented corrective actions and mistake-proofing in the assembly process to ensure that future shipments are properly assembled. Corrective action at the assembly plant was implemented on September 19, 2022. Recall Schedule :
Description of Recall Schedule : NR
Planned Dealer Notification Date : NR – NR Planned Owner Notification Date : NR – NR Purchaser Information :
The following manufacturers purchased this defective/noncompliant equipment for possible use or installation in new motor vehicles or new items of motor vehicle equipment: The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 22E-081
Page 4
The information contained in this report was submitted pursuant to 49 CFR §573
Name : NR Address : NR
NR Country : NR Company Phone : NR
* NR – Not Reported

**************************************************************************************************************

OMB Control No.: 2127-0004
Part 573 Safety Recall Report 22E-081
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Haldex Commercial Vehicle Systems NOV 21, 2022 NHTSA Recall No. : 22E-081 Manufacturer Recall No. : NR Manufacturer Information :
Manufacturer Name : Haldex Commercial Vehicle Systems Address : 10930 North Pomona Avenue
Kansas City MO 64153
Company phone : 816-801-2335 Population :
Number of potentially involved : 30,376 Estimated percentage with defect : 1 % Equipment Information : Brand / Trade 1 :
Model : Haldex Brake Product Corp ModulT Gen II Air Disc Brake Part No. : ModulT Gen 2 ADB Size : NR Function : NR
Descriptive Information : The recall population includes all brakes of this model manufactured at the Haldex Monterrey Facility starting with initial production 2/11/21 and ending when containment was implemented on 9/15/22
Production Dates : FEB 11, 2021 – SEP 14, 2022
Description of Defect :
Description of the Defect : The brake pad retaining assembly on certain Haldex air disc brakes (ADB) may contain an improperly installed retaining clip. If the retaining clip is improperly installed, the retainer bar may move and fail to retain the brake pads fully within the brake assembly, especially under road vibration conditions. Brake pads do not detach from the brake assembly but a loose brake pad, retainer bar, or retaining clip may come in contact with other nearby wheel components, and the retaining clip or retainer bar may fall into the road.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : Under certain road use conditions, an improperly installed retaining clip may enable the retainer bar and retaining clip to detach from the brake and may allow the brake pad to loosen. A loose brake pad may slightly reduce brake effectiveness, and may cut a tire valve resulting in a flat tire, and eventually
can cause damage to the brake pad or wheel. A detached retaining clip or Part 573 Safety Recall Report 22E-081 Page 2 retainer bar may come in contact with other vehicle parts and may fall into the roadway, creating road debris and a potential traffic hazard.
Description of the Cause : An incomplete manual assembly process resulted in inconsistent installation of the retaining clip and brake pad retainer bar. Identification of Any Warning NR
that can Occur : Involved Components : Component Name : Caliper
Component Description : ModulT Gen 2 Air Disc Brake Caliper
Component Part Number : H107891; H107893; H108541; H108542; H108584; H108586; H108587; H108589 Component Name : NR Component Description : NR Component Part Number : H107893 Supplier Identification : Component Manufacturer
Name : Haldex Brake Products Address : 10930 N. Pomona Avenue
Kansas City Missouri 64154
Country : United States 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 The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 22E-081 Page 3 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. Description of Remedy :
Description of Remedy Program : Haldex, their representative(s), or other trained technicians will inspect
and, if necessary, repair the improperly assembled spring bracket assembly. How Remedy Component Differs from Recalled Component : Identify How/When Recall Condition was Corrected in Production : A remedied component has the retainer bar fully seated in the notch with the retaining clip fully protruding through the retaining clip window on the retainer bar.
Haldex has identified the assembly plant at which the subject ADBs were produced and has implemented corrective actions and mistake-proofing in the assembly process to ensure that future shipments are properly assembled. Corrective action at the assembly plant was implemented on September 19, 2022. Recall Schedule :
Description of Recall Schedule : Manufacturers, Distributors and Fleets receiving the product are notified
by certified mail with details of the defect, remedy and instructions for inspection/repair if needed.
Planned Dealer Notification Date : OCT 12, 2022 – OCT 31, 2022 Planned Owner Notification Date : NR – NR Purchaser Information :
The following manufacturers purchased this defective/noncompliant equipment for possible use or installation in new motor vehicles or new items of motor vehicle equipment: The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 22E-081
Page 4
The information contained in this report was submitted pursuant to 49 CFR §573
Name : NR Address : NR
NR Country : NR Company Phone : NR
* NR – Not Reported

**************************************************************************************************************

OMB Control No.: 2127-0004
Part 573 Safety Recall Report 22E-081
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Haldex Commercial Vehicle Systems NOV 28, 2022 NHTSA Recall No. : 22E-081 Manufacturer Recall No. : NR Manufacturer Information :
Manufacturer Name : Haldex Commercial Vehicle Systems Address : 10930 North Pomona Avenue
Kansas City MO 64153
Company phone : 816-801-2335 Population :
Number of potentially involved : 30,469 Estimated percentage with defect : 1 % Equipment Information : Brand / Trade 1 :
Model : Haldex Brake Product Corp ModulT Gen II Air Disc Brake Part No. : ModulT Gen 2 ADB Size : NR Function : NR
Descriptive Information : The recall population includes all brakes of this model manufactured at the Haldex Monterrey Facility starting with initial production 2/11/21 and ending when containment was implemented on 9/15/22
Production Dates : FEB 11, 2021 – SEP 14, 2022
Description of Defect :
Description of the Defect : The brake pad retaining assembly on certain Haldex air disc brakes (ADB) may contain an improperly installed retaining clip. If the retaining clip is improperly installed, the retainer bar may move and fail to retain the brake pads fully within the brake assembly, especially under road vibration conditions. Brake pads do not detach from the brake assembly but a loose brake pad, retainer bar, or retaining clip may come in contact with other nearby wheel components, and the retaining clip or retainer bar may fall into the road.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : Under certain road use conditions, an improperly installed retaining clip may enable the retainer bar and retaining clip to detach from the brake and may allow the brake pad to loosen. A loose brake pad may slightly reduce brake effectiveness, and may cut a tire valve resulting in a flat tire, and eventually
can cause damage to the brake pad or wheel. A detached retaining clip or Part 573 Safety Recall Report 22E-081 Page 2 retainer bar may come in contact with other vehicle parts and may fall into the roadway, creating road debris and a potential traffic hazard.
Description of the Cause : An incomplete manual assembly process resulted in inconsistent installation of the retaining clip and brake pad retainer bar. Identification of Any Warning NR
that can Occur : Involved Components : Component Name : Caliper
Component Description : ModulT Gen 2 Air Disc Brake Caliper
Component Part Number : H107891; H107893; H108541; H108542; H108584; H108586; H108587; H108589 Component Name : NR Component Description : NR Component Part Number : H107893 Supplier Identification : Component Manufacturer
Name : Haldex Brake Products Address : 10930 N. Pomona Avenue
Kansas City Missouri 64154
Country : United States 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 The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 22E-081 Page 3 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. Description of Remedy :
Description of Remedy Program : Haldex, their representative(s), or other trained technicians will inspect
and, if necessary, repair the improperly assembled spring bracket assembly. How Remedy Component Differs from Recalled Component : Identify How/When Recall Condition was Corrected in Production : A remedied component has the retainer bar fully seated in the notch with the retaining clip fully protruding through the retaining clip window on the retainer bar.
Haldex has identified the assembly plant at which the subject ADBs were produced and has implemented corrective actions and mistake-proofing in the assembly process to ensure that future shipments are properly assembled. Corrective action at the assembly plant was implemented on September 19, 2022. Recall Schedule :
Description of Recall Schedule : Manufacturers, Distributors and Fleets receiving the product are notified
by certified mail with details of the defect, remedy and instructions for inspection/repair if needed.
Planned Dealer Notification Date : OCT 12, 2022 – OCT 31, 2022
Planned Owner Notification Date : OCT 12, 2022 – NOV 15, 2022 Purchaser Information :
The following manufacturers purchased this defective/noncompliant equipment for possible use or installation in new motor vehicles or new items of motor vehicle equipment: The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 22E-081
Page 4
The information contained in this report was submitted pursuant to 49 CFR §573
Name : NR Address : NR
NR Country : NR Company Phone : NR
* NR – Not Reported

**************************************************************************************************************

TECHNICAL MANUAL
Air Disc Brake ModulT Gen II
Technical Manual Table of Contents Section Page
Guide to using this Technical Manual . 3
General Safety Information 3
Legal and General Service Notes 4
ModulT Gen II Introduction 6
Product Offering 7
Tools 8
Exploded View . 9
Part Identification and General Information 10
ModulT Gen II DBT22LT Specifications and Bolt Torques . 11
Functional Operation . 15
Wheel-On Inspection Procedures 17
Wheel-Off Inspection Procedures . 18
Brake Caliper and Pad Inspection . 19
Brake Pad Replacement.
. 21
Rotor Health 25
Brake Chamber.
. 27
Slide Function Movement Measurement 30
Adjuster Mechanism Function Test . 31
Caliper Overhaul 34
Replacement of Slide Function Assembly 37
Caliper Removal and Replacement . 43
Troubleshooting . 44 2 Technical Manual ModulT Gen II Guide to using this WARNING This Gen II Technical Manual is for the exclusive Technical Manual
Through this manual, there are several HAZARD use of trained professionals within the commercial vehicle industry and related repair facilities.
Provide this Technical WARNINGS that must be read and adhered to in WARNING Manual to the person order to prevent possible personal injury and/or damage to equipment. Three signal words “DANGER“, “WARNING“, and “CAUTION“ are used to indicate
the severity of a hazard, and are preceded by the safety alert symbol. responsible for installation, operation, and maintenance of the product described herein. Without access to this information, installation, operation or maintenance of this product, may result in brake failure, equipment damage and possible personal injury. All installations DANGER Denotes the most serious hazard, and is used when and maintenance should be performed by qualified personnel. serious injury or death will result from misuse or failure to follow specific instructions. CAUTION Use only genuine Haldex replacement parts. The use WARNING Used when serious injury or death may result from of non-genuine Haldex replacement parts could result in unsafe and/or substandard product performance and misuse or failure to follow specific instructions. may void your warranty. CAUTION Used when injury or product/equipment damage WARNING It is very important that the distribution of brake may result from misuse or failure to follow specific instructions.
It is the responsibility and duty of all personnel involved in the installation, operation, and maintenance of the equipment on which this device is used to fully understand the ! Danger, ! Warning, and ! Caution procedures by which hazards are to be avoided. General Safety Information
All safety precautions shall be read and followed before any inspection, removal, or installation procedure described in this Technical Manual. force, between axles/vehicles, in a vehicle combination is adapted so that the brake force for each axle/vehicle is proportioned. If the brake force is not correctly distributed it can lead to excessive braking of a vehicle and/or one or more axles in the combination. This can result in overheating, accelerated wear, and damage to the disc brake, pads resulting in brake damage and failure. Following replacement of any essential components in the disc brake operating system. The disc brake operating system must also be checked and adjusted, to ensure safe operation of the vehicle. Failure to do so may result in damage to the disc brake, axle, and wheel brake components, and consequently personal injury or death. CAUTION Before operating the vehicle, the vehicle‘s disc brake operating system must be checked and adjusted necessary. Contact the vehicle manufacturer for relevant information. 3 ModulT Gen II
Technical Manual Legal and General Service Notes
Haldex Brake Products reserves the right to make changes to this document in the interest of technical progress without prior notice. For the latest update of the ModulT Gen II Technical Manual, please visit haldex.com and search for L30050. Haldex Brake
Products does not assume any liability due to incorrect or inappropriate parts being installed to the product or omittance of appropriate testing after servicing
the product.
This manual is subject to copyright laws, and the Haldex Brake Products reserve all rights. No part of this manual may be reproduced, copied, or translated in any form or by any means without the prior written permission of the Haldex Brake Products.
Brand names mentioned in this manual are not identified in all cases, but they nevertheless are subject to the provisions of trademark legislation.
The failure of any individual provision of this disclaimer to comply with current legal requirements does not affect the remaining provisions‘ validity.
Failure to follow the Safety Precautions
All safety precautions shall be read and followed before any inspection, removal, or installation procedure described in this Technical Manual.
Before operating the vehicle, the vehicle‘s disc brake operating system must be checked and adjusted (if necessary) in accordance with the relevant brake calculations. Contact the vehicle manufacturer for relevant information.
Replacement Parts
Always use parts that are approved for the vehicle, axle or disc brake. Following replacement of any essential components or parts in the disc brake operating system, must also be checked and adjusted (if necessary) in accordance with vehicle specifications.
Brake Force Distribution
It is very important that the distribution of brake force, between axles/vehicles, in a vehicle combination
is adapted so that the brake force for each axle/vehicle is proportioned.
If the brake force is not correctly distributed it can lead to overheating, accelerated wear and damage to the WARNING instructions in this disc brake, pads, rotors, tires and wheel components. Technical Manual may cause damage to the disc brake, axle, and wheel brake components, and consequently personal injury or death. 4 Technical Manual ModulT Gen II IMPORTANT!
It is important to take care when using chemicals and/or cleaning tools (e.g. knife, brush, etc.) to avoid damage or displacement of hoses, seals and other components. Proper personal safety equipment must be worn. Recycling
When replacing the disc brake or parts, the components removed must be recycled and destroyed in compliance with applicable environmental legislation, regulations and provisions.
Cleaning
For the disc brake to function correctly it is important to ensure it is kept clean and normal movement is not restricted by mud, ice, snow, objects, etc. Damage of this type may cause direct brake failure, malfunction or shortening of the service life of the disc brake.
Painting
The disc brake can be finished with paint that has trade approval for this purpose (automotive paint). Care must be taken to ensure that the paint layer does not cause damage or restrict the natural movement or operation of the disc brake. All contact surfaces, friction and rubber parts must therefore be protected or masked.
The following areas must not be painted:
All bellows, reset shaft protection plug, complete brake pads, the swept area of the rotor, the disc brake mounting surfaces to axle/brake chamber and all bolted connections. Shot-blasting
If the vehicle is shot-blasted, all rubber parts and pads on the disc brake must be protected. The brake chamber must be fitted (or any protective parts that have a similar sealing function). The shipping seal fitted to the brake chamber opening on a new disc brake does not provide adequate protection during shot-blasting.
The disc brake must be thoroughly cleaned after blasting to ensure that its natural movement is not obstructed by remnants of shot-blasting material. Check seals and rubber parts to make sure they have not been damaged. Also refer to the axle manufacturer’s instructions.
Installation
The disc brake must not be installed or treated in such a way that exposes it to normal thermal,
mechanical or chemical influences that can cause reduced braking effect or damage to vital components in the brakes. These influences/damages may result
in a shortened service life for the disc brake and its components, reduced brake effect or at worst total brake failure. 5 ModulT Gen II
Technical Manual ModulT Gen II Introduction 6 Technical Manual ModulT Gen II Product Offering
Calipers
Aftermarket Number Description Side With Carrier With Pads Bolt Pattern 790-H108542
790-H108541
790-H108584
790 H108586
790-H108587
790-H108589 DBT22LT RH W/CR W/P STD DBT22LT LH W/CR W/P STD DBT22LT RH W/CR W/P NSTD OffSET DBT22LT LH W/CR W/P NSTD OffSET DBT22LT RH W/CR W/P WD DBT22LT LH W/CR W/P WD Right Left Right Left Right Left Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Standard Standard NON STD NON STD
Wide Wide Repair Kits and Tools Aftermarket Numbers
790-22116 790-22117 790-95399 790-95397 790-95398 790-95231 790-22118 790-22060
790-22062
790-22063
790-22067
790-22068
790-22069 Description
Pad Accessory Kit Axle Pad Kit Mechanism Seal Kit
Slide Function Seal & Pin Kit Reset Shaft Kit Tool Box Kit Thrust Plate Rebuild Kit Bolt Kit
Bolt Kit Bolt Kit Bolt Kit Bolt Kit Bolt Kit Includes
2 pad springs, 1 pad retainer, 1 spring bracket, 1 reset shaft protection plug
384 copper-free pads, 4 pad springs, 2 pad retainers, 2 spring brackets, 2 reset shaft protection plugs
1 reset shaft protection plug, 1 mechanism bellow, 1 spring bracket, 1 grease tube
2 leading pin bearings, 1 leading pin spacer, 1 leading slide pin, 2 screws (M16x80), 1 small cup, 1 trailing composite bushing,
1 trailing slide pin, 1 large cup, 1 reset shaft protection plug, 2 slide pin bellows, 1 spring bracket
1 reset shaft protection plug, 1 mechanism bellow, 1 spring bracket, 1 grease tube
1 mandrel, 1 nut, 1 reinstall washer, 1 cup for slide function bearing, 3 mounting tools for the mechanism bellow, 1 3/4” drive, long reach, 14mm, 1 3/8” drive Torx T55 for the reset shaft, 1 special tool for removing the reset shaft complete, 1 threaded spindle for pull in/ pull out tools, 1 axial bearing for use with the threaded bar.
1 Gen II DBT22LT thrust plate, 1 mechanism bellows, 1 spring bracket, 1 reset shaft plug, 1 grease tube
M20X55mm M16X55mm M20X60mm M16X60mm M16X60mm M18X55mm 7 ModulT Gen II
Technical Manual Tools
Haldex ModulT Tool Kit complete
Part Number (P/N) 790-95231 A B
E C K
D L
H I J M
G
F Contents of Haldex ModulT tool kit Part No. 95231
A Mandrel 95219
B Nut 96820
C Clamp 95221
D Cup 95222
E Thrust plate bellows press 95224
F Caliper bellows press – Left 95225
G Caliper bellows press – Right 95226
H Socket Hex 95233
I Reset tool Torx T55 97240
J Pulling bracket 95210
K Spindle 96819
L Axial ball bearing 95423
M Toolbox 95237 8 Technical Manual ModulT Gen II 010 LH RH
Front of
trailer 015 010 Exploded View
010 Air Disc Brake Assemblies Complete – Left Hand & Right Hand
015 Caliper Housing
020 Carrier
030 Bearings – Leading Slide Function 040 Spacer
050 Leading Slide Pin 060 Slide Pin Bolt
070 Leading Protective Cup
080 Composite Bushing – Trailing Slide Function 090 Trailing Slide Pin
100 Trailing Protective Cup
120 Reset Shaft Complete
130 Reset Shaft Protection Plug
140 Bellows – Slide Function
150 Brake Pads
160 Pad Springs
170 Spring Bracket
180 Pad Retainer
190 Thrust Plate Bellow 210 Thrust Plate 160 170 180 020 030 120 040 030 150 050 150 160 080 090 130 060 070 140 210 060 100 190
140 9 ModulT Gen II
Technical Manual Part Identification
and General Information
Haldex Parts
It is vital that only Haldex original parts are used during all service replacement activities.
The use of non-Haldex parts can affect the function, performance and/or lifetime of the caliper. The use of non-Haldex parts will immediately terminate any warranty of the disc brake unit.
Label Description
A. Logo
B. OEM Part Number
C. A/M Part Number
D. Serial Number
The S/N contains 10 digits (YYWWLLSSSS) year/week/ assembly line/serial no. Gen II part number will be in the format Hxxxxxx. Please note the Gen I part number‘s format begins with 9xxxx. TYPE
P/N S/N A B C D
Assembled in MEXICO Marking Plate. Gen II Serial Number explanation:
Example 1 4 0 4 1 0 2 2 5 2 Comment Year Year Week Week Haldex No. Haldex No. Serial No. Serial No. Serial No. Serial No. 10 Technical Manual ModulT Gen II ModulT Gen II DBT22LT Specifications
The DBT22LT Gen II is a disc brake intended for a
430 mm rotor and used for applications with axles up to 23K lbs. (10.4 tonnes) GAWR. Maximum rated brake torque is 15K ft-lbs. (20 kNm).
Specification Characteristic Data:
• Design rated max brake torque 15K ft-lbs. (20 kNm)
• Max axle load 23K lbs. (10.4 tonnes)
• For wheel size 22.5”
• Max force 2.5K lbs. (11KN)
• Friction radius 6.8 in (173 mm)
• Max brake cylinder stroke 2.5 in (65 mm)
• Nominal brake ratio 15.4:1
• Mechanical efficiency > 93%
• Running clearance (min-max) 0.03 – 0.04 in (0.7 – 1.1 mm)
• Weight of complete disc brake unit, including pads
< 70 lbs. (< 32 kg). Rotor: • External diameter of brake rotor 16.9 in (430 mm) • Total thickness when new 1.8 in (45 mm) • Residual rotor minimum thickness 1.5 in (37 mm) Pad: • Total brake pad thickness 1.2 in (30 mm) WARNING Failure to follow the instructions in this • Backplate thickness 0.03 in (9.0 mm) • Minimum friction material thickness 0.08 in (2.0 mm) Options: • Carrier hole pattern. • Approved for 20K/23K (9/10.4 tonnes) axle loads. Technical Manual may cause damage to the disc brake, axle and wheel brake components and consequently personal injury or death. 11 ModulT Gen II Technical Manual Wear Limits Brake pads, min. lining thickness 0.08 in (2.0 mm) Differential pad wear between inner and outer pad during operation shall not exceed ± 0.06 in (± 3 mm) Brake rotor, minimum thickness 1. 5 in (37 mm)* *Note: Always refer to vehicle/axle manufacturers recommendations. Tightening Torques Haldex ModulT GenII ADB Bolts x2 for slide pins 133 ft-lbs + 70° (180 Nm + 70°) 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) Torque Tightening Pre-Torque (Dry) (Lubricated) Screw Thread M20x2.5 M16x1.5 M18x1.5 Offset (mm) 56 55 65 N-m 200 95 120 FT-LBS 145 70 88 N-m 675±34 350±34 450±30 FT-LBS 500 ±25 255±25 331±22 N-m 530±34 275±34 350±30 FT-LBS 390±25 200±25 258±22 Torque Plates Width (Inches) 1 1.225 Screw Length (mm) 55 60 Washer Thickness (mm) 3.5 ±0.5 3.5 ±0.6 The ModulT Gen II is a directional caliper. It is important that the correct caliper is installed in relation to the normal wheel / rotor rotation. Each caliper has a rotation arrow cast on the surface of the caliper where the pad retainer seats on the inboard side. Illustration provides a general overview with the rotation shown with a red arrow and the leading slide pin (AL) and the trailing slide pin (AT). AT AT Forward Rotation AL AL 12 Technical Manual ModulT Gen II Visual Inspection Points A visual inspection of the following should be made daily. 1. Check that service brakes are functioning properly before driving. 2. Check the parking brakes are functioning properly by trying to move vehicle with being applied and then released. 3. Check for any damage under unit and running gear. 4. Check for debris in caliper or wheels 5. Check for overheating signs on rotors and calipers. 6. Check for cracks in rotors. 7. Check PWI – Pad wear indicator for pad wear. 8. Check for missing, spring bracket, pad retainer, Preventive Maintenance Inspection Intervals Preventive maintenance inspection intervals, specified in the table below are maximum intervals. Depending on the vehicle application and type of driving, vehicle manufacturer’s service/inspection intervals may need to be more frequent. This table does not pad springs, and protective caps WARNING pre and post trip inspections. replace the need for daily C = Check I = Inspect M = Wheels Mounted R = Wheels Removed Visual Inspection Brake Adjustment Function Safety Check* Brake Pads Brake Rotor Plugs and Protective Cups Thrust Plate Guide Pins Brake Chamber Slide Pin Bellow Seals Thrust Plate Bellow Seals Slide Function Running Clearance CM / IM CM CM CM / IM CM CM CR IM IR IM IR CM IR CM CM IR IR IR CM IR IR IR CM / IM 13 31 17,18 and follow procedures in manual to repair failed part 19, 20, 21 11, 25, 26 38, 39, 40, 41 17, 20, 22 27, 28, 29, 34, 35 21, 37, 38, 39, 40, 41 34, 35, 36 37, 38, 39, 40, 41 11 * In accordance with industry recommended practices. 13 ModulT Gen II Technical Manual Functional Description C The ModulT features a floating monobloc caliper (C) and an integrated adjustment unit that compensates for brake pad wear. The adjustment unit, which is actuated B by the mechanism lever (A), extends the thrust plate and the inner brake pad (B) against the rotor, which then causes the caliper (C) to slide laterally, so that the outer brake pad (D) contacts the rotor. The caliper moves laterally on slide pins (E). In wheel positions where the D disc brake also serves as a parking brake, the unit is actuated by a spring brake chamber (F). A Functional description. E F E Slide pins and spring brake chamber. 14 Technical Manual ModulT Gen II Functional Operation Actuation / Release During a brake application the mechanism lever is actuated by operation of the brake chamber. The inner section lever presses the cross bar axially towards the rotor. The force is transferred from the cross bar via adjustment sleeves, adjustment screws and thrust plate to the inner pad. As the brake pad contacts the rotor the caliper moves laterally on the slide pins to allow the outer pad to contact the rotor. Upon release, a return spring forces the cross bar back to its rest position, allowing the design clearance between pad and rotor to be achieved. Automatic Adjustment Adjustment is based on the clearance principle. The braking sequence is split into three phases: design clearance, excess clearance, and elasticity phase. These phases take place when the brakes are activated and released. The mechanism lever activates the adjuster unit by means of a guide pin. The clearance between the guide pin and the slot in the adjuster unit housing determines the clearance between the brake pads and the rotor. The adjuster unit in turn rotates the adjustment sleeve which is threaded around the adjustment screw. The adjustment screws are prevented from rotating the adjuster sleeves by guides on the thrust plate. The second adjustment sleeve is synchronized and driven by a gear mechanism which consists of gear wheels attached to each of the two adjustment sleeves plus an intermediate gear wheel. Application During and through the forward stroke, the design clearance between pads and rotor is measured. The clearance between the guide pin which is attached to the mechanism lever and the slot in the adjuster unit housing determines the magnitude of the forward stroke before the adjustment process begins. 15 ModulT Gen II Technical Manual As the stoke continues if there is any clearance between the rotor and the brake pad when the thrust plate has moved axially through the design clearance the adjust unit rotates the adjuster sleeves. The adjustment screws are held in position by thrust plate and are therefore prevented from turning. Rotation of the adjuster sleeves in relation to the adjustment screws removes a percentage of the measured excess clearance. Within the adjuster mechanism, turning movement is transferred from the housing via adjustment spring, companion sleeve, one-way spring to the adjustment sleeves, which are threaded around the adjustment screws. When the stroke reaches full extension and the pads contact the rotor, the brake enters the elasticity phase, and the torque increases, the adjuster unit stops adjusting. The continued rotational movement which now occurs in adjuster unit is allowed by rotating housing in relation to adjustment spring. Release The first part of the return stroke is a combination of the elasticity phase and design clearance. Any residual part of the return stroke is excess clearance which is adjusted out during the subsequent braking. During the return stroke, return spring ensures the crossbar travels back. Brake force decreases during the first part of the return stroke. The guide pin moves to the opposite side of the slot in the adjuster unit housing where the transition to the design clearance phase starts. As the stoke continues to return the adjustment spring and companion flange are rotated in relation to the adjustment sleeve which remains stationary inside the adjuster unit housing. Movement between the companion flange and the adjustment sleeve is taken up by the one-way spring. During the last part of the return stroke, rotational movement in adjuster unit continues until mechanism reaches its resting position. The brake is now in its rest position. 16 Technical Manual ModulT Gen II Wheel-On Inspection Procedures Brake Pad Wear Inspection 1. Locate the brake pad wear indicator (PWI) pin and wear gauge on caliper. This will provide a quick visual indication of the total pad wear condition. WARNING Personal safety equipment must be wonr • This does not provide an accurate measurement when working with equipment. Brake Caliper Adjuster Inspection 1. Remove the reset shaft protection plug from the caliper. 2. Visually inspect the Reset Shaft Protection Plug for damage. Inspect bore of reset shaft for debris or corrosion. 3. Inspect reset shaft for unusual wear or damage. • Replace the plug or the reset shaft if there is evidence of wear or damage. 4. Using a T55 Torx (ensure the Torx tool seats fully into reset shaft), rotate the reset shaft clockwise until it stops rotating. The brake pads will be against the rotor. Reverse the reset shaft by de-adjusting and turning it counterclockwise 2 “clicks“. This verifies the operation of the brake caliper adjuster. of the wear on a particular pad (inner or outer), but rather the sum total of wear on both pads. The indicator cannot be used to determine if the pads are wearing evenly. 2. Observe with the PWI pin is in comparance to the pad wear indicator marking on the belly of the caliper housing. • If PWI pin is flush with caliper, a full wheel-off inspection must be performed to confirm that both pad material and rotor are with acceptable wear limits. Inspection of the visual wear indicator. 17 ModulT Gen II Technical Manual Wheel-Off Inspection Procedures WARNING working with equipment. Personal safety equipment must be worn when Blocking the wheels. 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. Release parking brake. Remove tire / wheel assembly. 18 Technical Manual ModulT Gen II Brake Caliper and Pad Inspection A WARNING working with equipment. Personal safety equipment must be worn when 1. Clean dirt and / or debris from surfaces, if necessary. 2. Check for signs of excessive heat exposure, discoloration, debris, etc. 3. The slide pin protection cups, reset shaft sealing plug, and caliper seal protection plug must be present and intact. a. The caliper seal protection plug (A) will never be removed. If missing, replace caliper assembly. 4. Remove the reset shaft sealing plug from the caliper. a. Visually inspect the plug for damage. Inspect bore of reset shaft for debris. 5. Inspect reset shaft for unusual wear or damage. a. Replace the reset shaft sealing plug or the reset shaft if there is evidence of wear or damage. Refer to reset shaft replacement section. 6. Insert two feeler gauges in between the caliper and the outer brake pad to measure the clearance. Position the feeler gauges in the upper and lower part of the brake pad back plate so an average clearance is measured. a. The normal running clearance is between 0.03 in – 0.04 in (0.7mm – 1.1mm). If there is no movement or the clearance is too small or too large refer to the fault-finding section. Correct location of the feeler gauges. 19 ModulT Gen II Technical Manual WARNING working with equipment. Personal safety equipment must be worn when Inspection of the visual wear indicator. B >2mm
A A Measuring the pad wear condition. 7. Remove the feeler gauges.
8. Reverse the reset shaft by de-adjusting and turning it counterclockwise 2 “clicks.”
a. Note: If further inspection of the brake caliper adjuster mechanism is needed refer to function test section.
9. Inspect the position of the pad wear indicator (PWI). The VWI provides an indication of total pad wear. Refer to percentage of wear specs on page 17, “Brake Pad Wear Inspection.“
a. Look for unusual conditions like excessive corrosion and high heat cycles.
10. Inspect that the two thrust plate pins are in their correct position. If pins are damaged or missing, refer to pages 34, 35 and 36 to replace thrust plate.
11. Inspect that the thrust plate with guide pins are free to move without obstruction.
12. On both brake pads measure the distance
from back plate to wear surface of the brake pad in four places.
a. Minimum lining thickness (friction material) is 0.08 in (2mm).
13. Measure and compare differential brake padB thickness between the inner and outer brake pads.
Up to 0.12 in (3mm) difference is acceptable.
14. Check the condition of the back plate.
15. Replace brake pads if they are worn out or if they are expected to be so before the next inspection. 20 Technical Manual ModulT Gen II Brake Pad Replacement WARNING
working with equipment. Removal
IMPORTANT! Personal safety equipment must be worn when Always remove the outer brake pad first. Always install the inner brake pad first.
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.
a. 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.
2. 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.
3. Remove the two pad springs (C).
4. 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).
5. Remove the pad retainer spring bracket (A). Slide Pin Bellows Inspection
1. Inspect both the leading slide pin and trailing slide pin bellows for signs of damage, punctures, or tears.
a. If the bellows are damaged replace as necessary with Haldex replacement parts, refer to caliper rebuild section. C Remove pad retainer and pad springs. E
D
Remove brake pads. Inspect the
slide pin bellows. 21 ModulT Gen II
Technical Manual 60mm Thrust Plate and Thrust Plate Bellows Inspection WARNING
working with equipment. Personal safety equipment must be worn when A Extend thrust plate for bellows inspection. Inspect the thrust plate bellows. Note: Do Not Over Adjust / Extend the thrust plate during the inspection procedure. Over adjustment / extension will cause the thrust plate to disengage from the mechanism and if done unintentionally may cause damage to the thrust plat bellow. Minimum distance between the caliper and thrust plate is 2.4 in (60mm).
1. Using a T55 Torx, manually turn the reset shaft clockwise to adjust the brake so that the thrust plate is extended, and the bellow can be viewed. Stop adjusting / extending when the distance between the inner pad face of the thrust plate and outer pad face on the caliper is 2.4 in (60mm).
2. Inspect the thrust plate bellow for signs of damage, punctures, or tears.
a. If the bellow is damaged replace as necessary, refer to caliper rebuild section (page 34).
3. If the bellow is in operational condition, manually de-adjust the thrust plate by turning the T55 Torx reset shaft counterclockwise until the position required to reinstall the brake pads.
Caliper Slide Function Inspection
1. With the brake pads removed; move the caliper by hand back and forth to check for slide pin movement. The caliper must be free to slide on the leading and trailing slide pins.
2. If the movement is felt to be obstructed or out of specification for the slide function, then further inspection is required.
3. If it is determined that the slide pins need replacement, refer to caliper rebuild section.
Note: Obstruction of the slide function can cause operatio- nal problems like hot brakes and uneven brake pad wear. It is important that all debris must be cleaned away from caliper moving components to ensure free movement. 22 Technical Manual ModulT Gen II WARNING Personal safety equipment must be 5. Install the outer brake pad into the caliper.
a. Note: Ensure the friction material faces the rotor. worn when working with equipment.
Installation
IMPORTANT!
Level N friction may be used in ModulT Gen I, but previous level A or B friction cannot be used in Gen II.
N Level Friction meets 2025 Legislation to eliminate copper to a level of less that 0.05%. For information, see Better Brake Law.
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. 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. 23 ModulT Gen II
Technical Manual WARNING Personal safety equipment must be worn when working with equipment. IMPORTANT!
Always install the inner brake pad first. B
A C Replace brake pads. IMPORTANT!
Ensure that friction material faces the rotor. IMPORTANT!
Use new parts in pad kit. Do not reuse old parts. OK OK Install new pad springs and pad retainer 24 Technical Manual Rotor Health
WARNING
working with equipment. Rotor Inspection ModulT Gen II Personal safety equipment B B
must be worn when 1. Look for wear, damages, and cracks on the brake rotor surfaces. Cracks that enter the cooling ducts via the outer or inner radius are not permitted.
2. Measure the thickness of the brake rotor using a brake micrometer or slide caliper. If the brake rotor has a wear ridge, the measurement can be performed using two spacers (B) (e.g. .25 in (5 mm) thick flat washers). Reduce the measured dimension by the total thickness of the two spacers (B). Acceptable crack length; less than 75% of swept width. Unacceptable crack length; more than 75% of swept width. A rotor‘s thickness should be measured in three places; the center, middle and outer edge of the rotor, using
a micrometer. Replace rotor if thickness varies more than 0.005” (.12mm) between any two points.
Minimum permitted thickness of a brake rotor is
1.5 in (37 mm). A rotor must be replaced if the wear limit has been exceeded. If resurfacing is necessary, be sure that at least 0.060” of material remains above the minimum rotor thickness for operating wear.
In addition to regular surface wear, disc brake rotors are subject to extreme temperature and torque on every application – and are often exposed to dirt, grease, salt, chemicals and other vocational hazards. The following notes will help you identify and address rotor conditions before they become problems.
Martensite Spotting
Extreme heat may cause changes to the metallic substructure of a rotor. Rotors may develop martensite; dark heat spots on the rotor that are hard, raised and brittle. Rotors in this condition should be replaced.
Lining Transfer
High operating temperatures or improper lining material may result in brake lining transfer, in which a layer of pad material becomes welded to the rotor surface.
Buildup may be removed by resurfacing the brake rotor. OK OK Martensite spotting. Lining transfer. 25 ModulT Gen II
Technical Manual Light heat checking. Heavy heat checking. Acceptable cracking. Unacceptable cracking. Grooving and scoring. Bluing and banding. Polishing. Heat Checking
Checking is a common condition caused by repeated heating and cooling of braking surfaces. Heat checks are short, thin, radial interruptions in the braking surface resembling multiple small and medium-size cracks.
Cracking
Heat checks may wear away with use or may become actual cracks or fractures in the rotor.
Replace rotors if cracks become over 0.060” (1.5mm) wide, over 0.060” (1.5mm) deep or extend over 75% of the rotor surface.
Rotor cracking may be caused by mishandling, brake imbalance, wear beyond thickness tolerance, or improper operation. Replace rotor if a crack extends through the brake surface or the mounting section.
A cracked rotor that is still considered operational should be re-inspected regularly to ensure a crack has not expanded.
Grooving and Scoring
Scores or grooves are often caused by contaminants between linings and rotors, worn linings, or lining plate contact. Replace rotor if the groove exceeds 0.060” deep or compromises minimum thickness for the rotor.
Bluing and Banding
Brakes operating at continued high temperatures may cause rotors to be discolored with blue marks or bands. It is not necessary to replace discolored rotors that still meet thickness specifications, but the cause of overheating should be identified and repaired.
Polishing
Rotors may exhibit a mirror-like braking surface, caused by lightly dragging brakes or improper pad selection. To correct polishing, sand the rotor surface and brake pads with 80 grit emery cloth. 26 Technical Manual ModulT Gen II Brake Chamber
Water and moisture entering into the caliper cavity can reduce the component‘s life expectancy.
Prevent water entering by using the correct brake chamber. Ensure the internal bellows (A) and the seal (B) between the brake chamber and caliper is undamaged. Also, make sure the brake chamber vent holes are unobstructed
At a minimum, the downward-facing drain holes must be open and free of obstruction. Other drain plugs can remain intact.
The Haldex ModulT Gen II DBT22LT uses either a 2.25” (57mm) or 2.5” (65mm) stroke brake chamber with a pushrod resting length of 15mm.
If an incorrect brake chamber is installed with an incorrect pushrod dimension, a partial brake application can occur that will result in a dragging brake. Remove ventilation drain plugs from bottom side of spring brake chamber. A WARNING
working with equipment. Personal safety equipment
most be worn when B INCORRECT CORRECT
20mm 15mm 76mm Stroke 65mm Stroke Inspect ball cup and seal of brake chamber lever. 27 ModulT Gen II B WARNING
A working with equipment.
Technical Manual Personal safety equipment must be worn when Clean mating surfaces of brake and chamber. 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). Secure brake chamber in the released position. F C D A
E Remove brake chamber items.
B 28 Technical Manual ModulT Gen II WARNING
working with equipment. Personal safety equipment must be worn when Brake 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 C
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 D
seats parallel. Place a small amount of general purpose grease in the ball cup of the brake chamber lever. F A
E 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. Fit the chamber to the caliper
with nuts and tighten. B
Fit hose connections. Remove ventilation drain plugs from bottom
side of spring brake chamber. 29 ModulT Gen II
Technical Manual Push brake caliper to inner position. C D Place dial indicator on carrier. Clean the measuring point. Slide Function Movement Measurement
Measurement:
1. With pads removed, push the caliper by hand as far as possible to inside of trailer.
2. Place the dial indicator on the carrier (position C) and clean the measuring point (D) with a cloth and place the dial indicator for measurement
in position D.
3. Tilt the caliper in the direction of the black arrows (No high force is required).
4. Set the dial indicator to zero.
5. Now tilt the caliper in the direction of the red arrows and read the measured play on the dial indicator.
6. If the bushing play measures over 0.08 / 2mm; the bushing needs to be replaced. The trailing bushing is made of a soft composite material. If a metallic sound is audible from the trailing bushing it must be replaced. LH
Road side
A RH
Curb side Measure play. A B (A) Leading bushing. (B) Trailing bushing.
B (A) Leading bushing. (B) Trailing bushing. 30 Technical Manual ModulT Gen II Adjuster Mechanism Function Test
Test of Adjustment Unit
Note: The function test can be carried out with the
wheel installed or removed. A
1. If not removed in a previous step, remove the reset shaft protection plug.
2. Using a T55 Torx, de-adjust the brake by turning the reset shaft counterclockwise until an audible clicking
sound is felt and heard when de-adjusting. This B
generally will be 4-5 “clicks”. The stop of the fully 2 1
retracted inner thrust plate position must be distinct, 4
but do not exceed 15 ft-lbs. (20Nm) in torque or leave it tightened in this position.
3. Leave the T55 Torx in position in the reset shaft. 4. Actuate the brakes 5 times by pressing and releasing the vehicles brake pedal through its full stroke. If a brake chamber is not installed, then actuate the brake chamber lever manually with a suitable tool.
5. The T55 Torx must rotate clockwise on each actuation, showing that the automatic adjustment function is working.
• If the T55 Torx rotates back and forth or not at all, then the adjustment function is not working correctly.
6. To verify faulty adjustment function, manually adjust the reset shaft by turning the T55 Torx clockwise 360 degrees, and then counterclockwise 180 degrees to ensure the adjuster is not jammed at the full de-adjust position.
• Also, note that once the excessive clearance is taken up by the adjuster the T55 Torx will naturally stop rotating. If in doubt, turn the
T55 Torx counterclockwise 180 degrees and then press the brake pedal again to check.
7. If the T55 Torx still rotates back and forth during actuation, then the adjustment function is defective, and the caliper must be replaced. De-adjustment of the reset shaft. x5
5 4 1
2 Brake actuation. 31 ModulT Gen II
Technical Manual “CLICK” 1 2 “CLICK” Initial brake pad setting. OK OK OK OK Correct fitment of protective plug WARNING
with equipment. Personal safety equipment must be worn when working IMPORTANT!
Leaving the reset shaft tightened in the de-adjust position could stop the adjustment function from working. After reaching the end stop position always adjust by turning the reset shaft clockwise 90 degrees, to activate the adjustment function. 32 Technical Manual ModulT Gen II WARNING
with equipment. Personal safety equipment must be worn when working Mounting of the Wheel
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. Mount the wheel. Secure spring brake in the active position. Remove the stops. 33 ModulT Gen II
Technical Manual Caliper Overhaul WARNING
working with equipment. Personal safety equipment must be worn when 52mm A Extract the thrust plate. Remove Thrust Plate Bellows
1. Fasten the disc brake securely in a vise with soft jaws. Ensure that the jaws of the vice do not damage the caliper.
2. Using a T55 Torx, manually turn the reset shaft clockwise to extract the thrust plate (A). Continue extracting until the thrust plate unscrews fully and becomes detached from the adjustment spindle.
The point at which the thrust plate becomes detached is when the gap between the thrust plate inner pad face and the caliper outer pad face becomes smaller than 2 in (52 mm).
3. Be careful when removing the thrust plate to not damage its internal threads or the external thread of the adjustment spindle.
4. Once the thrust plate becomes detached from the adjustment spindle, by hand pull off the thrust plate bellows from the thrust plate and caliper. Do not use any tools for this removal because damaging the sealing surfaces could cause water penetration leakage or seal corrosion upon reassembly.
5. Clean the thrust plate, thrust plate internal threads, thrust plate bellows sealing surfaces in the caliper. Ensure the parts are free from dirt, dust, debris, moisture, and corrosion. IMPORTANT!
Use a vacuum cleaner to clean surfaces. Do not use compressed air. IMPORTANT!
Take care with chemicals and cleaning tools to avoid damage or displacement of hoses, seals and other components. IMPORTANT!
Make sure that dirt and impurities do not enter the adjustment spindle opening. 34 Technical Manual ModulT Gen II WARNING
working with equipment. Personal safety equipment must be worn when Install Thrust Plate Bellows
IMPORTANT!
Make sure that the brake hoses are in good condition, that they are layed/ducted and fastened correctly. 1. Fasten the thrust plate in a vise with soft jaws. Take caution to not over tighten or damage the thrust plate.
2. Using Haldex tool P/N 95224 (C), firmly press the thrust plate bellows (A) into position on the thrust plate (B).
Verify the bellows is correctly seated in position on the thrust plate.
3. Apply the grease supplied with the replacement parts kit to the internal thread of the thrust plate Clamping arrangement for thrust plate. and the external thread of the adjustment spindle. OK OK
4. Remove the thrust plate from the vise. C
5. By hand, hold the thrust plate in position against the adjustment spindle. Using a T55 Torx inserted into the reset shaft, carefully turn counterclockwise, as
the thrust plate turns, carefully engage the thrust A
plate threads onto the adjustment spindle.
• Be careful not to cross thread the parts, if the thread becomes tight or locks, turn the reset shaft clockwise to release the thrust plate, then try again. • A clicking sound will be heard and felt when turning the reset shaft counterclockwise.
6. Shortly after the threads are engaged ensure that the two thrust plate guide pins correctly locate in their caliper holes.
7. Continue to retract the thrust plate until the dimension between the thrust plate inner pad face and the caliper outer pad face is 70 mm. Fitting the thrust plate bellows.
B 35 ModulT Gen II
Technical Manual 70mm Loading the thrust plate. F 8. Assemble Haldex caliper bellows press tool, load the assembled special tools into the caliper end of the thrust plate bellows.
9. By hand, firmly press on the tool with equal and parallel force so that the thrust plate bellows is pressed into position within the caliper.
10. The special tool can be removed, rotated, and then reapplied to aid the equal and parallel bellows seating.
11. Remove the tool and ensure the bellows is correctly seated around the thrust plate shaft and the caliper housing aperture.
12. Retract the thrust plate fully to its inner position by manually turning the reset shaft counter- clockwise. A clicking sound shall be heard and felt when retracting. The stop at fully retracted inner thrust plate must be distinct, but do not exceed 15 ft-lbs. (20 Nm) in torque or leave it tightened in this position. G Press in the thrust plate bellows. OK OK Adjustment screw bellows seated. 36 Technical Manual ModulT Gen II Replacement of Slide Function Assembly
IMPORTANT!
Where specified, only use the Haldex A
ModulT Tool Kit. WARNING
working with equipment. Personal safety equipment must be worn when Remove Slide Function Assembly
1. Use a small hammer and chisel to remove the leading and trailing protective cups (A). The protective cups are to be discarded, not re-used.
2. Using Haldex tool P/N95233 (3/4” long drive 14 mm hexagon), remove the two slide pin bolts (B). The bolts are to be discarded, not re-used. A
Remove slide protection cups and slide pin bolts. B B 37 ModulT Gen II
Technical Manual 3. Remove the carrier from the caliper by gently rocking the carrier to release it from the slide pins and bellows. Once released, press slide pins back enough to be able to lift out the carrier.
IMPORTANT!
D Be careful not to damage the slide pin
bellows sealing surfaces in the caliper. C Remove the carrier and slide pins. 4. By hand push out and remove the leading slide pin
(C) and the trailing slide pin (D).
5. By hand, carefully remove the two slide pin bellows (E). If required, use a small screwdriver to pry them out. Be careful not to damage the slide pin bellows sealing surfaces if using a tool to pry out the bellows.
6. Carefully follow steps 8 and 9 to remove the two leading bearings (F) and the spacer (G) and trailing composite bushing (H). E H G
F Remove the slide pin bellows,
slide bearings and compositeF side bushings. 38 Technical Manual ModulT Gen II 7. To remove the two bearings (F) and the spacer (G) L D A
on the leading side, assemble in sequence Haldex K B
tool (K), (L), (D), (A) and (B), as shown.
8. Once fitted correctly, turn the threaded tool clockwise which will pull out the two bearings (F)
and the spacer (G). F
9. The composite bushing (H) on the trailing side
should be removable by hand. K L
10. If the composite bushing is not removable by hand, D
assemble in sequence Haldex special tool (K), (L), (D), G
(A) and (B). 11. Once fitted correctly, turn the threaded tool clockwise which will pull out the composite bushing.
12. Clean the bearing and bellows sealing surfaces of the caliper to ensure they are free from dirt, moisture, corrosion, and damage. B Remove the leading slide bearing. 13. If the sealing surfaces have lost their protective H D L
surface coating, apply/smear a small amount of K
general-purpose grease over the whole area so when parts are refitted the grease will provide corrosion protection. A D K
B H Remove the trailing side composite bearing. Clean the bearing and bellows sealing surfaces. 39 ModulT Gen II WARNING
H
working with equipment.
Technical Manual Personal safety equipment must be worn when G
F Install the leading
slide bearings and trailing slide bushing.
F F G F C B
K K A
L A
F G F
C
B Tool assembly for leading slide bearings. OK OK Leading slide bearings installed. Install Slide Function Assembly
IMPORTANT!
Verify that the rotating bearing surface on
(L) is facing toward the flange on (K). 1. Carefully follow steps 2-4 below to install the two leading bearings (F) and the spacer (G) and step 5 to install the trailing composite bushing (H).
2. To install the two new bearings (F) and new spacer (G) on the leading side, assemble in sequence tool P/N’s 96819 (K), 95423 (L), 95219 (A), 95221 (C) and 96820 (B), preloaded with the new parts, as shown.
3. Once fitted correctly, turn the threaded tool clockwise which will pull into position the two bearings (F)
and spacer (G) complete.
4. Stop once the bearings are seated in the correct position up to the inside lip of the bearing location surface, see figure 60. It is important the bearings are seated correctly but not over tightened as this may cause damage.
IMPORTANT!
The trailing side composite bushing, installed by hand, must be indexed correctly or the slide function of the brake will not be correct. 5. To install the new composite bushing (H) on the trailing side, by hand, push the composite bushing into place, until it bottoms out. Ensure the index lug locates correctly in the caliper slot.
6. No tools or high force are required for this fitting process, excessive force may cause damage.
If the bushing is not indexed correctly, the H Insert the trailing side composite bushing. slide pin and protective cup may not fit. 40 Technical Manual ModulT Gen II 7. By hand, firmly push the two new slide pin bellows into their caliper locations ensuring that the bellows are seated correctly in position. It is important to confirm the bellows are correctly seated within the caliper, bottoming out against the caliper location shoulder. Failure to seat the bellows may compromise the sliding function of the brake.
8. By hand, insert the leading slide pin into the bearings and the trailing slide pin into the composite bushing. The longer slide pin is fitted into the leading side. One end of the slide pin has a machined groove and is inserted fist (no grease is required).
9. Verify the bellows location ring is fitted correct and in one piece. By hand, locate the bellows onto the end of the slide pins. Ensure the bellows and the bellows location ring seat correctly on the slide pins. Failure to do so may compromise the sliding function of the brake.
10. Clean the brake pad contact surfaces on the carrier, caliper, and thrust plate. A wire brush can be used, however, ensure not to damage any of the bellows. Check for wear on the carrier pad abutment area, if present, replace carrier.
11. Lift the carrier into position to attach the caliper while ensuring that the slide pins fitted with bellows do not interfere or obstruct. If necessary, push out the slide pins slightly by hand while lowering the carrier. Hold the carrier in position while the two bolts are threaded.
12. Using a 14mm x 3/4” long allen socket (Haldex P/N 95233), continue to tighten and torque the slide pin bolts to 130 ft-lbs. + 70° (180 Nm + 70°).
13. Install the protective cups as illustrated (AT and AL) using a soft-headed mallet.
a. Note: the cups are different sizes, the larger cup is fitted to the trailing side pin (AT) and the smaller cup is fitted to the leading side (AL). The leading protective cup (AL) seats raised from the caliper casting surface and the trailing protective cup (AT) seats nearly flush. Installing the cups at an angle or damaging the ends may compromise the sliding function of the caliper. OK OK Install slide pin bellows. D Insert slide pins. C Reseat carrier and fixing bolts. B AT
AL
B OK OK OK OK AL
AT Seat the protection cups. 41 ModulT Gen II
Technical Manual B A
X-Ring Remove the reset shaft. “CLICK”
OK OK Reset Shaft Removal and Replacement
1. Remove the reset shaft protection plug.
2. Insert Haldex tool P/N 95210 and pull out the reset shaft by locating the tool in the two holes of the reset shaft.
3. Clean the reset shaft bore and surrounding surface. Ensure the area is free from dirt, dust, debris, moisture, and contaminants.
4. Using a T55 Torx, insert the reset shaft into the caliper by hand.
a. Note: A new reset shaft is assembled complete with O-ring and lubricated, no additional grease or lubrication is required. If reusing a reset shaft, apply a thin layer of grease to ensure the O-ring is not damaged upon installation.
5. Push the reset shaft into position by hand, no impact or force is required. Use of force may damage the shaft. The reset shaft will click into position in the center of the gear wheel when fully engaged. Replace the reset shaft. 42 Technical Manual ModulT Gen II Caliper Removal and Replacement WARNING
with equipment. Removal Personal safety equipment must be worn when working 1. Before removing caliper from axle, ensure that brake chamber (page 28) is removed and secured; as well as the brake pads.
2. Loosen bolts with long wrench, one at a time, ensuring top bolt is still supporting caliper.
3. Confirm the caliper is supported.
4. Remove the bolts completely. Replacement
1. Re-install the caliper. (Never reuse bolts) 3 4 2 5 6 Caliper Installation
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 page 7 for bolt kit numbers. Bolt tightening sequence SHOULDER BOLT BRAKE SPIDER INNER CALIPER BOLTS CAUTION 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. OUTER CALIPER BOLT SHOULDER BOLT IN OUTER MOUNTING HOLE
SHORT GUIDE PIN BRAKE CALIPER LONG GUIDE PIN 43 ModulT Gen II
Technical Manual Troubleshooting
If you are experiencing no or low brake force, uneven braking, accelerated pad wear or unusual noise/vibration please review the following list. No or low brake force
Pads are worn out Replace pads WARNING
with equipment. Personal safety equipment must be worn when working The difference between inner/outer pad wear
is greater than 0.2 in (3 mm)? This is not necessarily a fault and will not normally have any negative effect on
the ADB function. But if the difference is >0.2 in (>3 mm) you need to be aware of the reason why in order to ensure that the system continues to operate correctly. The following potential causes should be considered and investigated: ADB installation
Sliding functions: check that nothing is blocking the calipers full range of motion (including but not limited to strapped hoses and suspension components). On steering axle, ensure that nothing is interfering with caliper, over the full steering range motion. Mechanical wear
Pads used in wet, dirty and/or salty environments will wear faster than pads running in dry, clean conditions. Differential pad wear can occur between pads on a single wheel end. Dust shields will help eliminate excessive pad wear. Driving input
Aggressive braking can result in uneven pad wear as it results in higher than average braking temperatures. Frequent stopping and high-speed stops will also result in high running temperatures, again causing uneven pad wear. Too small or too large of a running clearance may indicate that the adjuster may not be functioning and should be checked. Perform an adjuster mechanism function test. The lack of proper clearance may indicate that the slide function is seized. Perform a slide function movement measurement test. Running clearance Review pad/disc clearance, to determine if in acceptable limits. The lack of proper clearance may indicate that the slide function is seizing. Perform a slide function test. The adjust mechanism is not functioning correctly. Perform an adjuster mechanism function test. If a failed test replace caliper. 44 Technical Manual ModulT Gen II No or low brake force (continued)
Is pad/disc clearance OK? Conduct initial setting + function checks. Rotor Review rotor health section found on page 23, 24 Brake Chamber Review air pressure in the brake chamber okay? Measure with pressure gauge. Evaluate for leaks. Ensure that the drain plug has been removed from the brake chamber housing. Is air pressure in the brake chamber OK? (Measure with a pressure gauge at the brake chamber) Implement remedial measures according to vehicle manufacturer’s instructions. Has the drain plug been removed from the brake chamber housing? Does the mechanism and caliper move freely? Remove the drain plug located at the lowest point of the brake chamber. Conduct initial settings and function check. Has one of the drain plugs been removed from the brake chamber housing? Remove the drain plug located at the lowest point. Noise / vibrations from the brake Can the pads move freely in the carrier? Are there non-permitted cracks/grooves on
the brake rotor? Is the brake rotor’s
run-out within specified parameters? Remove the brake pads, clean the pads, carrier and caliper, then refit. Probably need to change the brake rotor. See the vehicle manufacturer’s instructions for more information. If not then probably need to change the brake rotor. See the vehicle manufacturer’s instructions for more information. Are the disc brake and its components fixed
to the axle as specified? See the vehicle manufacturer’s instructions for more information. 45 ModulT Gen II
Technical Manual Notes: 46 Technical Manual Notes: ModulT Gen II 47 ModulT Gen II 48 Technical Manual
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