802569

Heavy-Duty Splined Disc Kit (SD-1, SD-2, SD-3, SD)

803129

(Dana-brand) Trailer Axle Pad and Rotor Shield Kit

803130

Axial Drive Axle Pad and Rotor Shield Kit

802948

Pad Shield Kit

K032135

Vertical Drive Axle Pad and Rotor Shield Kit

K061768

FF Vertical Pad and Rotor Shield Kit

K061770

FL Vertical Pad and Rotor Shield Kit

K123970

Steer Axial Rotor Shield Kit

K109114

Pad / Rotor Measuring Tool

Table 2 – Maintenance Kits (continued)
See the Bendix Quick Reference Catalog (BW1114) for maintenance kits for other Bendix® brand air disc brakes.
* Not compatible with continuous wear-sensing brakes.

20

4.0.1 GENERAL INFORMATION
ABOUT BENDIX® AIR DISC BRAKE
MAINTENANCE

4.1 AIR DISC BRAKE DUST SHIELD KIT

When working on Bendix® Air Disc brakes, please note
the following:
•

Read and follow the Safe Maintenance Practices on
page 2.

•

Depending on the particular axle, the technician may
need to remove the caliper/carrier to allow sufficient
access to perform the work.

•

CAUTION: When using a hoist to support the air
disc brake, do not attempt to use the pad retainer
bar as a bracing point as it is not designed to
support the weight of the brake. Instead, use a
brace (or chain) wrapped around the entire brake
to attach the hoist.

•

When replacing bearings – or for any other maintenance
procedure where the technician needs to remove the
caliper/carrier assembly from the vehicle to perform the
maintenance – replacement caliper/carrier bolts will
be required. Please note that due to the high torque
required, the original bolts cannot be reused. The bolts
are available from the vehicle manufacturer.

•

Not all wheels and valve stems are compatible
with Bendix Air Disc Brakes. Use only wheels and
valve stems approved by the vehicle manufacturer
to avoid risk of valve stem shear and other
compatibility issues.

Kit

Air Disc Brake Dust Shields
Pad Kit (axle set)
Caliper Kit (rationalized)
Carrier Kit
Service Actuator
Spring Brake Actuator
Tappet/Boot Kit (wheel-end kit)
Guide Pin, Seal, and Boot Kit (wheel-end kit)
Hubs
Bendix® Splined Disc® Rotor Attaching Kit
Rotor

See
Section
4.1
4.2
4.3
4.3
4.3
4.4
4.5
4.6
4.7
4.7
4.7

4.1.1 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.
NOTE: Most torque plates manufactured after January 1,
2007 have the required torque plate tabs to permit these
shields to be mounted.
This shield kit includes a brake pad shield, a rotor shield
and the required attaching hardware for use in Bendix®
ADB22X®, ADB22X®-V, and ADB22X®-LT Air Disc Brake
applications where external contamination and excessive
road debris is a concern. Brake pad and rotor shields can
greatly reduce damage and/or premature wear of pads and
rotors under these conditions.
During installation, verify that once the shield(s) are
installed they will not come into contact with any vehicle
components, suspension, housings, etc. through the full
range of motion of the wheel. Keep in mind the particular
use of the vehicle, the orientation of the brake on the axle
and torque plate, the proximity of other axles, and/or the
wheel/tire being used.
4.1.2 Remove and discard the spring clip and washer
from the pad retainer pin. Remove and retain the
retainer bar and retainer pin. Position the pad shield
as shown and reinsert the retainer bar. Install the
retainer pin. Use the included spring clip and washer
to secure the retainer pin. Check that the pad shield
is held securely in place by the retainer bar. See
Figure 30 or 31.

Remove
Brake Pads?

Remove Caliper/
Carrier from
Vehicle?

Remove
Actuator from
Caliper?

Section 4.2

Section 4.3

Section 4.4

Not Typically
Yes
Yes
Yes
No
No
Yes
Yes
Yes
Yes
Yes

NA
No
Yes
Yes
Not Typically
Not Typically
Typically
Typically
Yes
Yes
Yes

NA
No
Yes
Yes
Yes
Yes
Typically
Typically
Yes
Yes
Yes

Table 3 – Other Required Sections for Maintenance Kits

21

Spring
Clip

Washer
Spring
Clip

Washer

Pad Shield

Pad Shield

Rotor Shield

Rotor Shield
Fastener

Torque
Plate
Fastener

Fastener

Lock
Washer

Torque
Plate
Fastener
(with
Washer)
Rotor
Shield

Rotor
Shield

Figure 30 – Drive or Steer Axle Exploded View with
Inset Showing Rotor Shield Installation

Figure 31 – Trailer Axle Exploded View with Inset
Showing Rotor Shield Installation

4.1.3 Drive or Steer Axle Rotor Shields (See Figure
30.) Position the rotor shield between the torque
plate and the rotor. The supplied cap screws pass
through the mounting tabs in the torque plate and
install into the shield. Torque cap screws to 44 ft-lbs
(59.6 N•m).

4.2 PAD REPLACEMENT

4.1.4 Trailer Axle Rotor Shields (See Figure 31).
Position the rotor shield with the torque plate
between the shield and the rotor. With one
(supplied) lock washer in place on each cap screw,
pass the screws through the shield before mounting
onto the threaded torque plate holes. Torque the
cap screws to 24 ft-lbs (32.5 N•m).
NOTE: The installation of air disc brake shields does not
eliminate the need for periodic maintenance and inspection
of the air disc brake and entire wheel end for damage and/
or wear. In addition, the truck and trailer manufacturer’s
specific criteria for the brake shield requirements on air
disc brakes should be consulted before either installing or
removing air disc brake shields from a wheel end(s).

22

4.2.1 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.
Important: If the vehicle is equipped with spring brakes,
cage the spring brakes on all axles to be worked on.
Consult the vehicle manufacturer’s instructions as
necessary. For Bendix® piston-style, see Section 4.4.

Electronic Wear Sensor
(if installed)

104
Cable
Protection
Plate

Harness
Connector

Version 1

Version 2

101
Sensor

101
Sensor

Harness
Connection
Built-in
Sensor

104
Cable
Protection
Plate

106
Mounting Pin

103
Cable to
Electrical Supply

iSense Pro
Adjuster
Cover
103
Cable to
Electrical Supply

44
45
11
26
44
Pin

2

11 Pad Retainer Bar

ard
tbo
Ou

12

37

26 Spring Clip

Figure 33 – Pad Retainer Bar Removal

d

oar

Inb

45 Washer

61

Figure 32 – Pad Replacement
4.2.2 Raise the complete axle to be worked on until the
tires clear the ground. See the vehicle maintenance
manual instructions for removing the wheels.
4.2.3 If the air disc brake is equipped with a pad wear
sensor (see top of Figure 32), note how the wire
is installed in the wire shield then remove and
discard the wire shield. Disconnect the wearsensing harness from the jumper harness before
removing the pads. The wear-sensing harness and
wire shield will be replaced with the brake pads.
If the air disc brake is equipped with a continuous
wear sensor (see top/bottom of Figure 32), then
proceed to the next step.
4.2.4 See Figure 33. Remove and discard the spring
clip (26) and washer (45).
4.2.5 While pressing against the pad retainer bar, remove
the pin (44). Discard the pad retainer bar (11).

4.2.6 See Figures 32 and 34. With the spring brake
released (or caged), remove the adjuster cap (37)
using the tab, taking care not to move the shear
adapter (61). NOTE: Two sizes of adjuster caps
are supplied in kits; use the same size as before in
step 4.2.20.
4.2.7 Inspect the shear adapter (61). If significant
corrosion and/or damage is present, remove the
adjuster adapter using needle-nose pliers and
replace with the adapter supplied in the kit and
clean as necessary.
37
Cap

23 Adjuster
61 Adapter

37
Cap

Tab

Figure 34 – Exploded
View of Adjuster and
Adapter

Tab

Figure 35 – Cap
Installed: Tab Location

For illustration purposes, the exploded view (Figure 34)
shows the adjuster (23) and shear adapter (61) separated.
When using the adjuster mechanism, always have the
shear adapter installed on the adjuster.
23

CAUTION: Never turn the adjuster (23) without the
shear adapter (61) installed. The shear adapter is a
safety feature and is designed to prevent too much
torque being applied when the adjuster (23) is turned.
The shear adapter (61) will fail (by breaking) if too much
torque is used.
NOTE: For wheel-ends with spring brakes, if a shear
adapter fails, always double-check to verify that the spring
brake has been released (or caged). If the spring brake
is applied, release or cage the brake (ensure that the air
system pressure is at least 90 psi but not greater than the
vehicle governor cut-out pressure) and start the procedure
again. Always try to use the vehicle’s air system pressure.
In an emergency, shop air can be used, but never exceed
the vehicle’s governor cut-out pressure.
If the shear adapter fails, you may attempt a second
time with a new (unused) shear adapter. In cases where
a second failure of the shear adapter confirms that the
adjustment mechanism is seized, the caliper must be
replaced.
4.2.8 Use a 10 mm, six-point box wrench (See Figure 36)
to turn the adjuster counterclockwise until sufficient
space exists to remove the brake pads. A clicking
noise occurs each time the adjuster turns.

4.2.9 See Figure 37. Move the caliper fully inward and
remove the inboard pad, then move the caliper fully
outward and remove the outboard pad.
4.2.10 Repeat the pad removal procedure for the other
end of the axle.
4.2.11 Inspect the brake pads as shown in Section 3.3.
4.2.12 Inspect the brake rotor (See Section 3.4).
4.2.13 Inspect the guide pins (See Section 3.5).
Important: To maintain optimal braking, Bendix strongly
recommends that whenever brake pads are replaced,
the complete axle set be replaced together. Use only
pads which are permitted by the vehicle manufacturer,
axle manufacturer, and/or disc brake manufacturer.
Failure to comply with this may invalidate the vehicle
manufacturer’s warranty.
Before installing the brake pads, use the adjuster to
fully retract the tappets to provide adequate clearance.
4.2.14 Clean the surfaces that will come in contact with
the brake pad.
Caution: When installing pads and retaining springs,
where appropriate, use heavy duty gloves and always
keep fingers away from potential pin hazard areas.

CAUTION! Avoid overloading or damaging the adjuster
shaft. Do not use an open‑ended wrench since it may
damage the adjuster shaft.

2

12

Figure 38 – Pad Retaining Spring Installation
Figure 36 – Backing Off the Adjuster for Pad
Removal
d

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Inb
ard
tbo
Ou

If the air disc brake is equipped with a continuous
wear sensor (see top/bottom of Figure 32), then
proceed to the next step.

Inboard Pad

Figure 37 – Pad Removal

24

4.2.15 If the air disc brake is equipped with a pad wear
sensor (see top of Figure 32), insert the wear
sensors into position in the new brake pads. Route
the sensor cable through the cable protection plate
channel and secure the place with the mounting
hardware retained at disassembly. Refer to Section
4.2.

4.2.16 Install the blue pad retaining springs (2) onto the
brake pads (12) by inserting one end of the spring
onto the lug at the top of the brake pad (See Figure
38). Carefully apply enough force to permit the
second lug to fully engage, taking care to keep
fingers etc. away from the spring as it seats.
4.2.17 Pull the caliper fully outward and install the outboard
pad. Move the caliper fully inward and install the
inboard pad.

4.3 C
ALIPER/CARRIER/ACTUATOR
ASSEMBLY

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.
Figure 39 – Running Clearance Adjustment
4.2.18 Using a 10 mm, six-point box-end wrench, turn the
shear adapter (61) clockwise until the pads contact
the rotor. NOTE: Do not use an open-ended wrench
as this may damage the adapter. See Figure 39.
4.2.19 Using the same tool, turn the shear adapter (61)
counterclockwise and listen for the sound of three
(3) clicks as the mechanism backs-off (increases)
the running clearance. See Figure 36.
4.2.20 Select the correct replacement adjuster cap from
those supplied with the kit. Lightly grease adjuster
cap with Renolit® HLT2 white grease (part number
14525) and install the cap.
4.2.21 Push the new pad retainer bar (11) into the groove
of the caliper. Press down on the pad retainer bar,
and insert the pad retainer pin (44), with the pin
pointing downwards, where possible. See Figure