and allow the wedge fork (“A” in Figure 48) to be
inserted.
CAUTION: DO NOT INSERT THE SCREWDRIVER
MORE THAN ¼ IN.. Take care not to damage the
inner sealing face (see arrow “X” in Figure 48).
Gouges or grooves will prevent a good seal and
will require that the caliper be replaced.

12
Pad
Assembly

13

13
Tappet
and Boot
Assembly
61
Shear
Adapter

T15

A

22
161
Tappet
Bushing

6 Adjuster
Cap

22 Inner Seal

Figure 46 – ADB Exploded and Section Views
4.5.2 Pad Removal: follow Sections 4.2.1-4.2.11 for
removal of the brake pads.
4.5.3 Inspect the Brake Rotor. See Section 3.4

Tappet and Boot Assembly (13) Removal
CAUTION: NEVER EXTEND THE TAPPET MORE
THAN 1.75 in. (44.5 mm). See Figure 47. Overextending the tappet will result in the tappet losing
engagement with the threads of the synchronizing
mechanism. Since the mechanism can only be set at
the manufacturing plant, the caliper/carrier assembly
must be replaced if this happens.
B

13

X
13
161

Figure 48 – Wedge Tool Use
4.5.5 The tappet and boot assemblies (13) can then be
removed from the threaded tubes (16) by using the
wedge fork (T15). Be sure to orient the wedge tool
with the tapered side towards the tappet.
4.5.6 Remove the old tappet bushings (161).
4.5.7 Retract the threaded tubes by turning the shear
adapter (61) counterclockwise.
4.5.8 See Figure 49. Carefully remove the inner seal
using one or two flat-blade screwdrivers as shown.
CAUTION: Do not insert the screwdrivers so far
that they come into contact with the threaded
tubes. Damage to the threaded tubes would
require that the brake be replaced.

13

Extend Less
Than 1.75 in.
(44.5 mm)

Figure 47 – Permitted Tappet Extension
31

12
16

22
A

46

16
Figure 49 – Inner Seal Removal

Figure 50 – Use of a New Brake Pad as a Spacer

4.5.9 Inspect the inner sealing face for damage. If damage
is found that would cause the inner seals not to be
able to seal properly, the caliper/carrier assembly
must be replaced. Clean the area around the inner
seal.
4.5.10 Inspect the threaded tubes (16). See Figures 50 and
51. Extend the tubes, but by less than 1.75 in. (44.5
mm), by turning the shear adapter (61) clockwise.
Inspect the threads for rust, corrosion, or damage
etc. If there is evidence of damage to the threads,
significant rust, or corrosion, the caliper/carrier
assembly must be replaced.
If the technician is working with the caliper on the
vehicle, the technician may place a new brake pad
(12) into the outboard gap to help avoid the loss
of thread engagement of the threaded tubes. See
Figure 50.
If the work is being carried out at a workbench, the
technician may insert a 2.76 in. (70 mm) spacer
(See callout “E” in Figure 51) into the caliper (1) to
help avoid the loss of thread engagement.
4.5.11 For threads that are in good condition, grease the
threads with white grease (Part No. 14525 or
K021964). Before installing the replacement inner
seals (22), retract the threaded tubes by turning the
shear adapter (61) counterclockwise.
NOTE: If the shear adapter fails while you are retracting
the threaded tubes, you may try again with another
(new) shear adapter. If this also fails, this indicates
that the adjuster mechanism is damaged and the
caliper must be replaced.

32

2.76 in.
(70 mm)

16

E

1

Figure 51 – Use of a Spacer (off-vehicle inspection)
To install inner seals where the caliper is on the vehicle:
4.5.12 Position the replacement inner seal (22) over the
threaded tube (16). See Figures 52 and 53 for the
tools and installation arrangement used. Position
the L1 (T03 + T09) with the short spacer (T03) in
position as shown in Figure 54. Guide the tool over
the end of the threaded tube (16). Install the new
inner seal (22) into position by rotating the adjuster
nut on the T03 portion of the tool, using an openended wrench.

T09

T09

T03

Figure 54 – On-Vehicle Inner Seal Tool (L1)

T04

T03

Figure 54 – Off-Vehicle Inner Seal Installation Tool (L2)

L1

L2

22
X
16

T09

16
X

L2

22

Figure 53 – On-Vehicle Inner Seal Installation

Figure 55 – Off-Vehicle Inner Seal Installation

To install inner seals where the caliper has been
removed from the vehicle:

4.5.15 Install the new tappet bushing (161) onto the center
post of each threaded tube (16) by hand. By hand,
ease the tappet bushings onto the center post of
the threaded tubes and they will snap into position.

4.5.13 Position the replacement inner seal (22) over the
threaded tube (16). See Figures 54 and 55 for
the tools and installation arrangement used. The
threaded tubes need to be retracted to allow the tool
to be inserted. Use the combination tool L2 (T04 +
T03 + T09) with the long spacer (T04) as shown in
Figure 55. Since the installation tool is guided by
the center post of the threaded tube, advance the
tube a small amount to align the tool and the center
post. Install the new inner seal (22) into position by
rotating the adjuster nut on the T04 portion of the
tool using an open-ended wrench.
CAUTION: To confirm that the inner seal has been
correctly installed, begin to extend the threaded tubes
(16) by turning the shear adapter clockwise by 4-5
turns. Watch as the threaded tube extends. Inner seals
that are installed correctly WILL NOT ROTATE as the
threaded tube extends.

4.5.16 The sealing seat in the caliper for tappet and boot
assemblies (13) must be clean and free of grease.
Wipe the opening with a clean shop rag. Place a
tappet and boot assembly (13) in position over the
center post and tappet bushing.
To install tappet and boot assemblies where the caliper
is on the vehicle:
4.5.17 See Figures 56, 57, and 58. Use tool B1, comprising
tools T01, T02, and T03 to press the boot into
position. The tool is then reversed, and the nylon
disc (T24) is inserted into the T01 “cup” (combination
tool ‘B2’). Holding the T02 handle, turn the nut on
the T03 tool to fully install the tappet onto the tappet
bushing (161).

4.5.14 NOTE: Inspect the tappet/boot kit to determine
if the tappets supplied are already pre-greased
(a plastic cover should be present — be sure to
remove the cover when installing the tappet). Only
in the case of kits that are not pre-greased will the
installer need to apply grease to the tappets. In all
cases, the threaded portion of the tubes will need
to be greased. Retract the threaded tubes.
33

Figure 56 – On-Vehicle Tappet and Boot Installation
Tool (B1 - with T24 Installed, B2)
13

B1

Figure 59 – Off-Vehicle Tappet Boot Installation Tool
(B3, with T24 Installed, B4)
B3

13
161

Figure 57 – On-Vehicle Tappet Boot Installation

13

Figure 60 – Off-Vehicle Tappet Boot Installation

B2

13

B4
Figure 58 – On-Vehicle Tappet Installation
To install tappet and boot assemblies where the caliper
is removed from the vehicle:
4.5.18 See Figures 59, 60, and 61. Retract the tappets,
as needed, in order to have room to install the
tappets. Use tool B3, comprising tools T01, T02,
and T03 to press the boot into position. The tool is
then reversed, and the nylon disc (T24) is inserted
into the T01 “cup” (combination tool ‘B4’). Holding
the T02 handle, turn the nut on the T03 tool to fully
seat the tappet onto the tappet bushing (161).

34

Figure 61 – Off-Vehicle Tappet Installation
4.5.19 Check that the tappets are firmly attached to the
bushings by gripping and pulling lightly on them by
hand. Confirm that the tappets are able to rotate a
small amount on the tappet bushings by grasping
and turning them by hand. Finally, using a box-end
wrench on the shear adapter, extend the threaded
tubes outward, and check that the boots are held
in place. Retract the tappets.
4.5.20 Reinstall the caliper/carrier assembly, if it was
removed from the vehicle (See Section 4.3).
4.5.21 Reinstall the brake pads (See Section 4.2).

Vertical
Bolt Style
(with
bushing)

Bushing
(6)
Guide Pin (Short)
(4)
Caliper Bolt
(Short)
(39)
Cap
(Large)
(68)

Inner
Boot
(9)

Ring
(58)
Horizontal
Mounting Bolt
Style Shown:
See Inset Above
for Vertical
Bolt Style (with
bushing).

Shear
Adapter
(61)
Adjuster Cap
(Two alternate
caps supplied
in kit)
(37)

Ring
(58)
Inner
Boot
(9)

Guide Pin
(Long) (5)

Guide
Bushing
(Long) (7)

Caliper Bolt
(Long)
(40)
Cap (Small)
(10)

KIT CONTENTS
Item

Description. . . . . . . . . . . . . . . . . . . . . . . Quantity

4
5
6
7
9
10
37
39
40
58
61
68

Guide Pin (Short) . . . . . . . . . . . . . . . . . . . . . . . .
Guide Pin (Long). . . . . . . . . . . . . . . . . . . . . . . . .
Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Guide Bushing (Long). . . . . . . . . . . . . . . . . . . .
Inner Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cap (Small). . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjuster Cap (Two versions supplied) . . . . . . .
Caliper Bolt (Short). . . . . . . . . . . . . . . . . . . . . . .
Caliper Bolt (Long) . . . . . . . . . . . . . . . . . . . . . . .
Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shear Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . .
Cap (Large). . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1
1
1
1
2
1
2
1
1
2
1
1

(White grease is also supplied - not shown)

Figure 62 – Guide Pin Exploded View

4.6 GUIDE PIN AND BOOT ASSEMBLIES

4.6.1 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® brand piston-style spring brake
chambers, see Section 4.4.

These procedures are typically carried out with the
caliper/carrier removed from the vehicle (may be
carried out with the air disc brake installed). In cases
where the caliper/carrier assembly is removed from
the vehicle, NEW fasteners must be used and properly
torqued during reinstallation. Use only fasteners
approved by the vehicle manufacturer.
NOTE: This maintenance procedure requires specialized
tools.
The full Bendix® air disc brake tool kit – part number
K029164 – includes the tools needed for the guide pin and
boot installation. See Table 6.
Note that a smaller Bendix tool kit – part number
K029107 – may be used where only the guide pins will be
serviced.

35

Bendix
Part No.

Description

Bendix
Part No.

Description

T05

1-3/8 in.
diameter disc

T14

Brass nut

T06

1-1/2 in.
diameter disc

T16

Dimpling tool

T07

2 in.
diameter sleeve

T20

8 in. bolt

T08

2-1/8 in.
diameter disc

T21

Half sleeve

T10

8 in.
bolt

T26

Cap
installation tool

T12

3-7/8 in.
long sleeve

T27

Cap
installation tool

T13

10 in.
bolt

Typical Tool View

Typical Tool View

Table 6 – Bendix ® ADB22X®, ADB22X® -V and
ADB22X® -LT Air Disc Brake Guide Pin and Seals
Replacement Tools (a washer is also included)

4.6.2 Remove the wheel. Refer to the vehicle manufacturer’s recommendations.
4.6.3 Remove the brake pads. See Section 4.2.
4.6.4 In most cases, the actuator should be removed. See
Section 4.4. In the case of spring brake actuators,
they should be caged before removing the brake
assembly.
4.6.5 In nearly all cases, the air disc brake caliper/carrier
will need to be removed from the vehicle in order to
complete this procedure. See Section 4.3.

Figure 63 – Punch
Guide Pin Cap (10)

Figure 64 – Guide Pin
Cap (10) Hole

4.6.6 Place the brake on a workbench and, using a vice,
secure it by the carrier.
4.6.7 Use a small chisel or similar tool to punch a hole
close to the center of the guide pin cap (10) of the
short guide pin, taking care to only insert the chisel
a small amount. Using the hole just made, pry the
cap off and discard. See Figures 63-65.

36

Figure 65 – Pry to Remove Figure 66 – Use a Small
Chisel to Remove the
Guide Pin Cap (10)
Guide Pin Cap (68)
4.6.8 Remove the other cap (68) that covers the long
guide pin, by using a small chisel and hammer to
apply light blows to the cap, with the chisel aimed
away from the casting. See Figure 66. Discard both
caps.

4.6.9 Using a 14 mm hex