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NHTSA ID Number: 10191597

Manufacturer Communication Number: SD-23-7541

TSB/Document Date: 2021-05-04


Summary

BendixeBay logo ADB22X, ADB22X-V, and ADB22X-LT Air Disc Brakes (ADB) use a floating caliper design to provide foundation braking on all axles of heavy commercial vehicles, buses, and trailers. BendixeBay logo air disc brakes provide safety and performance as well as ease of service.


inserting through the
guide pin channel –
engage the brass
nut (T14). Always
double-check that
the brass nut is
correctly in place in Figure 71 – Install the
the bushing before Removal Tool
beginning to extract
the bushing.

5.6.15 Prepare to remove
the short guide pin
bushing by locating
the bushing (6) tab,
and using a small
chisel (narrower than
the tab) or similar
tool, remove the tab
as shown in Figure Figure 74– Remove
74, by striking low on the Tab that Holds the
the base of the tab. Bushing in Position
Remove the tab with a magnet and use a clean
shop cloth to remove any excess debris. Note
that in some cases, the tab may be in the opposite
(outer) slot in the bore.
Washer

T21

Grease the bolt prior to each use

T20

T14

Figure 75 – Short Guide Pin Removal Tool

39

5.6.16 Use the tool combination shown in Figures 75 and
76 (comprising T14, T20, T21, and a washer) to
remove the bushing (6). Screw nut (T14) onto the
assembly by hand, then tighten the bolt (T20) using
a box end wrench to draw out the bushing. Discard
the removed bushing, and verify that the bore is
clean by wiping with a shop cloth.
T20

6

T14

Figure 76 – Sectional View: Short Guide Pin Bushing
Removal

Installation of the Fixed Guide Pin Brass
Bushing

5.6.17 Clean the caliper upper and lower surfaces around
the bushings.
5.6.18 Clamp the carriereBay logo in a vise so that the guide channel
is vertically oriented.
Washer

T14

T08

7

Washer

T21

T13

T14

Grease the bolt prior to each use

T16

Figure 77 – Long Guide Pin Bushing Installation and
Dimpling Tool
5.6.19 Place the washer and thread the brass nut (T14) on
to the bolt (T13) followed by the flange (T08). See
Figure 77.
5.6.20 Place a new brass guide bushing (7) on the dimpling
tool (T16) and insert it into the caliper bore.

7

View
“A”

View
“B”

View
“C”

Figure 78 – View “A” and “B”: Draw the Brass
Bushing into Position. View “C”: Lock the Bushing
into Position
5.6.21 Check that the flange (T08) is in an upright position
at the top of the caliper recess as you draw the brass
bushing (7) up, by turning the brass nut (T14), until
the dimpling tool bottoms on the caliper. When it
reaches the correct position, the brass bushing
extends out of the guide pin channel 0.039 in.
(1 mm).
5.6.22 With the dimpling tool (T16) in position, tighten the
screw in its base until it contacts the dimpling screw
housing. The movement of this screw forces three
points outwards, leaving indentations in the brass
bushing. See Figure 78, view “C”.
5.6.23 Unscrew the dimpling screw out approximately 0.75
inches (20 mm). Loosen the brass nut (T14) and
rotate the dimpling tool (T16) 60 degrees. Repeat
the dimpling process by tightening the brass nut
(T14) and then tighten the dimpling screw until it
contacts the dimpling screw housing. Back out the
dimpling screw approximately 0.75 inches (20 mm).
The brass bushing (7) is now held in position by the
six dimples made by the tool.
5.6.24 Remove the installation tools and check the brass
bushing (7), removing any burrs, being careful not
to leave any metal filings in the bushing. Coat the
inside of the bushing with the white grease included
in the kit.

Installation of the Floating Guide Pin Bushing

5.6.25 To install the bushing (6) into the short guide pin
side, first inspect the bore for corrosion, damage
etc. Clean as necessary.

40

5.6.26 P l a c e t h e n e w
bushing (6) in
position so that
when drawn into
position, the tab
will align with the
slot in the casting.
With the tab aligned,
place tool (T14) over Figure 79 – Position the
the bushing and tap New Bushing
lightly. To position
the bushing, see
Figure 79.
T20

Grease the bolt prior to each use

Washer

5.6.29 Coat the inside of the bushing (6) with a light coat
of the white grease included in the kit.
5.6.30 Install the two identical inner boots (9) by first
cleaning the area where the inner boots will be
installed and inspect for corrosion. If the sealing
surface of the caliper is damaged, replace the
caliper.
Grease the bolt prior to each use

Washer

T08

T10

T07

Figure 82 – Short Guide Pin Boot Installation Tool

T05

T06

T08

T14

Figure 80 – Short Guide Pin Bushing Installation
Tool
5.6.27 Use the tool combination shown in Figure 80 to
draw the bushing (6) into the caliper. Also see
Figure 81, to see the orientation (with tool T14 at
the top). Hand tighten the nut (T14) into position.
Then tighten the bolt (T20) using a box end wrench
or socket to draw the bushing (6) into the caliper
until the bushing (6) contacts the machined step in
the bore. Remove the tool.

5.6.31 See Figure 83. Place
a boot into the sleeve
installation tool
(T07), making sure
that the inner bellows
are arranged close
to the side walls of
the tool and will not
be damaged during Figure 83 – Position the
installation. Also New Boot in the Sleeve
check that the outer Installation Tool (T07)
edge of the boot
rests on the front
edge of the tool.
5.6.32 Using 70 in-lbs (8 Nm) of torque maximum, tighten
bolt (T10) to install the inner boot.
5.6.33 Repeat the installation procedure for the second
inner boot.

T14
6
Bushing Stop
T08
T06
T05
T20

Washer

Figure 81 – Guide Pin Bushing Installation
5.6.28 Using a punch, bend the tab into the groove by
aligning the punch with the upper part of the tab
and tapping the punch with a hammer.

5.6.34 Check that the boots are held securely in place and
that no damage occurred during installation.
5.6.35 See Figure 84. To
install the guide
pins, first lubricate
both guide pins with
the white grease
supplied. Insert the
guide pins into their
respective bores
Figure 84 – Place the
with the grooved end
Retaining Ring onto the
towards the bellows.
Groove in the Guide Pin
Fit the lip in the end of the inner boots (9) into the
groove of the guide pins. Push on each ring (7)
ensuring that the boot (9) is engaged onto the end
of the guide pins (4 or 5).

41

5.6.36 With the caliper resting on a bench, slide the carriereBay logo
into place with a slight rocking motion, taking care
that as you do so, the inner boots and guide pins
are seated in their proper place on the carriereBay logo.
5.6.37 Identify the two caliper bolts (39) and (40).
With the shorter bolt placed in the floating pin
bushing (4), and the longer bolt placed in the fixed
pin bushing (5), begin to tighten the bolts. With the
caliper/carriereBay logo in a vice, continue installing the bolts
to a torque of 133 ft-lbs (180 Nm). Finally, tighten
each bolt an additional 90º (ninety degrees).

Installation of the Guide Pin Caps
5.6.38 See Figure 85. Place
Boot
the caliper/carriereBay logo as- Compressed
sembly on a bench
so that the inner
boots are fully compressed, check that
the bores are clean
and dry (e.g. free
Figure 85 – Boots Must
from lubrication).
Be Compressed Fully
During Cap Installation
Note: It is important that the inner boots are fully
compressed during this procedure to ensure that
the least amount of air is retained within the guide
pin channel. If too much air is trapped, the bellows
can potentially be damaged during the operation of
the brake. It is also important that the technician
double-check that the retaining rings remain in their
correct position during this procedure.

5.6.39 Clean the two caps, and check that the caliper
surfaces where the caps will be installed are clean
and have no signs of damage.
5.6.40 Select one cap to
install. Using the
correct press-in
tool – the smaller
cap (10) installs
in the long guide
pin side using tool
(T26), and the larger
Figure 86 – Boots Must
cap (68) installs
Be Compressed Fully
in the short guide
During Cap Installation
pin side using tool
(T27) – place the cap
in position, using the
machined channel in
the caliper to assist
in centering the tool.
Use a hammer to tap the cap into position. See
Figure 86. Note that the tool needs to remain
perpendicular to the channel to prevent damage
during installation. Note that, after installation, the
smaller cap (10) extends 0.08 in. (2 mm), and the
larger cap (68) extends 0.61 in. (15.5 mm).
Repeat for the second cap.
5.6.41 Check that the guide pins move freely when the
carriereBay logo is moved laterally, and that air is not trapped
within the inner boots, and that the boots (9) and
ring (58) are in the proper position before continuing
with the installation.
5.6.42 Install the caliper/carriereBay logo (See Section 5.3).
5.6.43 Install the brake chamber (See Section 5.4).
5.6.44 Install the brake pads (See Section 5.2).

42

5.7 BENDIXeBay logo® SPLINED DISC® HUB ROTOR
DRIVE HUB
Intermediate Elements
(Spacers)
Spring
Elements
(Retention
Brackets)
ABS Tone
Wheel
& Fasteners

STEER HUB

Wheel Studs

Intermediate Elements
(Spacers)
Spring
Elements
(Retention
Brackets)

Hub
ID Label

Splined Disc Rotor

Wheel Studs

Hub

ID Label

ABS Tone Wheel
(Press On)

Above: BendixeBay logo® Splined Disc® Rotor on Aluminum Drive Hub

Above: Splined Disc Rotor on Aluminum Steer Hub

Figure 87 – Splined Disc Rotor Examples - Exploded Views
BendixeBay logo® Splined Disc® Hub Rotors are designed to assist
vehicle maintenance by typically allowing the rotor to be
serviced without requiring the entire hub/rotor assembly
be replaced.
Periodic inspection of the Splined Disc attachment
hardware is recommended to ensure optimum braking
performance. BendixeBay logo recommends verifying the torque on
the spring element fasteners whenever a brake inspection
is performed.
NOTE: Anytime that the entire hub/rotor assembly
is removed, BendixeBay logo recommends that the wheel seal
also be replaced at the same time, USING A HIGHTEMPERATURE SEAL. Follow the wheel seal and/or
vehicle manufacturer's guidelines for full installation
instructions. Adjust the bearings and refill bearing
oil to vehicle manufacturer's specifications.
When replacing a splined disc rotor, BendixeBay logo strongly
recommends that the brake pads be replaced (as an
axle set.) Contact 1-800-AIR-BRAKE (1-800-247-2725),
option 2, for the appropriate brake pad kit. Rotor
replacement necessitates the removal of the pads.
CAUTION: Follow all safe maintenance practices,
including those listed on page 2 of this document.
Park the vehicle (by other means than the foundation
brakes) on level ground and chock the wheels. Also
read the vehicle manufacturer's recommendations.
When installing pads, where appropriate, use heavy
duty gloves and always keep fingers away from
potential pinch hazard areas.
BendixeBay logo® Air Disc Brakes (ADB) are precision-engineered
braking mechanisms. The “friction couple” braking
characteristics have been carefully optimized and the rotor
design and materials have been matched with special
formulation brake pads for optimal performance, therefore
use only genuine BendixeBay logo® brand parts and brake pads.

BendixeBay logo air disc brakes are precision-engineered braking
mechanisms. The “friction couple” braking characteristics
have been carefully optimized and the rotor design and
materials have been matched with special formulation
brake pads for optimal performance, therefore use only
genuine BendixeBay logo® brand parts and brake pads.

Rotor Replacement

5.7.1 Before removing the brake pads it is strongly
recommended that the air disc brake adjuster
mechanism be checked for correct operation (See
Section 4.1). When replacing brake pads, BendixeBay logo
strongly recommends that the pads be replaced as
an axle set.
5.7.2 Refer to the vehicle manufacturer’s recommendations
and release (or cage) spring brakes and remove the
wheel.
5.7.3 Remove the pads (See Section 5.2).
5.7.4 Remove the air disc brake (See Section 5.3).
5.7.5 Remove the hub rotor assembly.
Note: Follow the vehicle manufacturer's guidelines for
removal of the wheel hub and rotor assembly from the
vehicle in lieu of these instructions, where available.
CAUTION: Be sure to secure both the rotor and hub
before removing the retention clips.
U-Shape rotor removal Caution: The fasteners
typically use a thread lock compound. Secure
the hub-rotor prior to removal. Remove and discard
the fasteners attaching the rotor to the axle. Discard
the rotor.
5.7.6 Remove and discard the ten spring elements.
5.7.7 On drive axles, the ABS tone ring must also be
removed. (See Figure 87.) Retain for reinstallation.
43

5.7.8 Use suitable hand tools to remove the intermediate
elements (spacers). Remove all the right-hand
intermediate elements (spacers) of each set first
and then the rotor can be turned slightly to release
the remaining intermediate elements (spacers).
In all cases, take care not to damage the hub and
its teeth. Remove and discard the intermediate
elements (spacers) and retention clips attaching
the rotor. Discard the rotor.
5.7.9 Following industry standards, clean and inspect the
hub before installing the rotor. Look for corrosion
and/or damage to the hub and inspect the wheel
speed tone ring. Where necessary, consult the hub
manufacturer's guidelines for more details.

B

B-B

KEY
1 - Wheel Hub
2 - Splined Disc Rotor
3 - Intermediate Elements (Spacers)

Figure 90 – Installing Intermediate Elements
(Spacers)

B
KEY
1 - Wheel Hub
2 - BendixeBay logo® Splined Disc® Rotor
3 - Intermediate Element (Spacer)
4 - Spring Element (Fastener), including retention clips

Figure 88 – Rotor with Cross-Section View

Figure 91 – Intermediate Elements (Spacers
Installed)
hub does not exceed 0.015 in. (0.4 mm). If a gap is
found that exceeds this maximum value, verify the
installation of new intermediate elements (spacers).
Replace the wheel hub if the excess gap cannot
be corrected with proper installation of new rotor
retaining hardware.
5.7.11 Install the ten new spring elements included in the
kit in an evenly-distributed cross-pattern sequence.
Torque to 22.1 ft-lbs (30 Nm).

Figure 89 – Rotor Installation

ROTOR INSTALLATION

5.7.10 See Figures 88 through 92. Place the rotor into
position on the hub. Install the new intermediate
elements (spacers) as shown in Figure 90. With
all the intermediate elements (spacers) correctly
inserted into position, verify that the gap between
the intermediate elements (spacers) and the wheel
44

5.7.12 Where the tone ring was removed during step 5.7.7,
reinstall the tone ring. Use a professional grade
fastener compound, such as Loctite® Blue 242®, on
the fasteners. Torque to 19-22 in-lbs (2.1-2.5 Nm).
5.7.13 Reinstall the hub rotor assembly using a new
high-temperature wheel seal, following the vehicle
manufacturer’s instructions.

Figure 92 – Fasteners Installed
5.7.14 Reinstall the air disc brake (See Section 5.3).
Supporting the air disc brake by all necessary
means, attach the brake to the anchor plate
using six bolts and washers as required (BendixeBay logo
recommends the original bolts not be re-used).
Torque to vehicle manufacturer's specifications.
If torque values and bolts are not specified by the
vehicle manufacturer, then torque according to the
chart shown in Table 4. Be sure to select bolts
with the same thread pitch, length, and grade as
originally provided from he vehicle manufacturer.
5.7.15 Reinstall the brake pads (See Section 5.2).

6.0 U-SHAPE ROTOR INSTALLATION
Following industry standards, clean and inspect the hub
before installing the rotor. Install the new rotor to the hub,
using the cap screws included in most kits. (Note: the
cap screws have pre-applied thread-locking compound).
Torque to 200-225 ft-lbs (271-305 Nm). See Figure 93 for
the suggested torque sequence.
Note: Because of the many different installations, fasteners
may not be provided in this kit. In these cases, obtain
fasteners from the vehicle manufacturer. Install per vehicle
manufacturer recommendations for torque and retention
compound (e.g. Thread-locking compound).

Suggested Rotor
Torque Sequence for 10
fastener hubs. For other
fastener configurations,
please see the vehicle
or axle manufacturer’s
specifications.

Figure 93 – Torque Sequence
45

NOTES

46

NOTES

47

CONTACTING BENDIXeBay logo
foundationbrakes.com

BendixeBay logo on-line information is available 24/7/365. It’s your complete BendixeBay logo resource.

BendixeBay logo Technical Assistance Team

• For direct personal technical support, call the BendixeBay logo Tech Team at 1-800-AIR-BRAKE
(1-800-247-2725), option 2. Representatives are available to assist you Monday through
Thursday, 8:00 am to 6:00 pm and Friday, 8:00 am to 5:00 pm ET, or email the BendixeBay logo
Tech Team at: techteam@bendixeBay logo.com.

To better serve you, please collect the following information before you call the
BendixeBay logo TechTeam, or include this information in your email:
BendixeBay logo product model number, part number, and configuration.
• Vehicle make and model.
• Vehicle configuration. (Number of axles, tire size, etc.)
• System performance symptoms: When do they occur?
• What troubleshooting/measurements have been performed?
• What BendixeBay logo service data literature do you have or need?

SD-23-7541 © 2021 BendixeBay logo Commercial Vehicle Systems LLC, a member of Knorr-Bremse • 4/21 • All Rights Reserved

48

Printed on recycled paper

1...45678

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TSB/Document ID: SD-23-7541

Replacement Service Bulletin Number:

MFR Communication Date: 2021-04-22

MFR Internal Campaign ID/Software Version:

Communication Type: Service Bulletin/Repair Instructions

NHTSA Components: SERVICE BRAKES, AIR

MFR Component System:

MFR Component Subsystem:


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