Haldex Modult User Manual

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INSTALLATION/SERVICE MANUAL

› TM

Air Disc Brake

Important Notices

General

The products described within this literature, including without limitation, product features, speciﬁcations, designs, availability and pricing are subject to change by Haldex and its subsidiaries at any time without notice. This document and other information from Haldex, its subsidiaries and authorized distributors provide product and/ or system options for further investigation by users having technical expertise. It is important that you analyze all aspects of your application and review the information concerning the product or system, in the current literature or catalog. Due to the variety of operating conditions and applications for these products or systems, the user, through their own analysis and testing, is solely responsible for making the ﬁnal selection of the products and systems and assuring that all performance, safety and warning requirements are met.

› TM

AIR DISC BRAKE INSTALLATION/SERVICE MANUAL (L30048)

• Never exceed recommended component or system pressures.

• Do not attempt to install, remove, disassemble or assemble a component until all recommended procedures have been read and are fully understood. Use only the proper tools and observe all precautions pertaining to the use of those tools. Components with stripped threads or damaged parts should be replaced rather than repaired. Repairs requiring machining or welding should not be attempted unless speciﬁcally approved and stated by the vehicle or component manufacturer.

• Prior to returning the vehicle to service, make certain all components and systems are restored to their proper operating condition.

Replacement Parts/Retrot Components

Safety and Important Precautions

• All company and vehicle manufacturer’s safety procedures must be followed when installing the ModulT Air Disc Brake.

• Always wear proper personal protective equipment, including approved eye glasses.

• Never work on or under a vehicle unless it is parked on a level surface and its wheels are blocked to prevent it from moving.

• Never work on a vehicle air brake system when the engine is running. Where circumstances require that the engine be in operation, extreme caution should be used to prevent personal injury resulting from contact with moving, rotating, leaking, heated or electrically charged components.

• Drain all air pressure from the air system before beginning any installation, service or repair.

• Never connect or disconnect a hose or line containing pressure. Never remove a component plug unless it is certain that all system pressure has been depleted.

Use appropriate spare parts documentation when obtaining spare parts. Only use Genuine Haldex replacement parts in the repair process.

Questions?

If you have any questions on this product or any of the innovative products offered by Haldex, contact your local distributor for complete details. Technical Service or Troubleshooting help can be obtained by calling Haldex Technical Services Department at 800.643.2374, follow prompts.

ModulTService Guide

Introduction Page

1.1 General Information .........................................................3

1.2

1.3 Functional Description / Technical Information ......................................6

The Haldex ModulT

..........................................................5

Safety Precautions

2.1 General Information .........................................................9

2.2 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.3 Adjustment of Control System/Valves ...........................................10

2.4

2.5 Recycling .................................................................11

2.6 Cleaning

2.7 Surface ﬁnishing for Disc Brake ................................................12

Brake Chamber

.................................................................

............................................................11

Initial and Final Procedures

3.1 General Information ........................................................13

3.2

3.3 Inspection Procedures . ......................................................15

3.3.1

3.3.2 Inspection intervals .........................................................15

3.3.3

3.3.4 Inspections ...............................................................17

3.4

3.5 Final Procedure ............................................................33

Initial Pr

General Information ........................................................

Daily Safety Check

Function T

ocedure

...........................................................

..........................................................16

est ..............................................................31

Replacement Procedures

4.1 General Information ........................................................35

4.2

4.3 Replacement of PWI (Pad Wear Indicator) ........................................41

4.4

4.5 Replacement of Brake Chamber ...............................................48

4.6

4.7 Replacement of Slide Function Assembly ........................................58

4.8

4.9 Replacement of Disc Brake ...................................................71

Replacement of Brake Pads ...................................................

Reset and Installation of PWS (Pad W

Replacement of Thrust plate Bellows

Replacement of Reset Shaft Complete

ear Sensor) and PWIS ( Pad Wear Indicator Sensor)

............................................53

...........................................69

.....

Specications

5.1 Wear Limits ...............................................................73

5.2

ightening Torques

.........................................................

Tools

6.1 Haldex ModulT Tool Kit complete ..............................................74

6.2

Special tools for Haldex ModulT

...............................................

Fault Finding

7 Symptoms and actions .......................................................75

Component List and Exploded view

8.1 Component List ............................................................78

8.2

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Exploded view

.............................................................79

ModulT Service Guide

Note

This Service Guide is intended for the exclusive use by trained persons within the commercial vehicle industry and related workshops.

The content of this manual is not all-inclusive and not legally binding and Haldex Brake Products assumes no liability as a result of its use. All information contained in the manual does neither represent ensured characteristics of the product nor represent a guarantee. Haldex Brake Products reserves the right to make changes in the interest of technical progress without prior notice.

No liability is assumed as a result of incorrect or inappropriate parts being ﬁtted to the product or the omittance of appropriate tests after the servicing of the product. Use appropriate spare parts’ documentation when obtaining spare parts. Use only genuine Haldex spare parts in repairs.

This manual is subject to a copyright of Haldex Brake Products that reserves 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 Haldex Brake Products. Brand names mentioned in this manual are not identiﬁed as such in all cases, but they nevertheless are subject to the provisions of trademark legislation.

In case of conﬂicting language versions of this manual, the English original prevails.

The failure of any individual provision of this disclaimer to comply with current legal provisions does not affect the validity of the remaining provisions.

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ModulTService Guide

Introduction

1.1 General Information

This Haldex ModulT Service Guide is divided up into chapters, these chapters are sequenced in the same way that a user should read and follow the manual.

Chapter “1. Introduction” provides a general overview of this service guide and the ModulT disc brake.

It is important to carefully read chapter ”2. Safety Precautions” before starting any workshop procedures. This is to inform the user about the safety measures and the potentially hazardous situations which, if not avoided, could result in serious injury or death!

Chapter “3. Initial and Final Procedures” describes the start and ﬁnish activities necessary to be able to carry out inspection and replacement work. It also describes the function test for the ModulT disc brake.

Consult chapter ”3.3. Inspection Procedures” for information and instruction on inspecting the ModulT disc brake. Chapter “3.3.2. Inspection Intervals” is useful for the recommended disc brakes inspection intervals. Here the Inspection Intervals table displays how frequent the different brake components shall be inspected and on which pages the check instructions are to be found.

If any inspection shows that a replacement activity needs to be performed, continue to the appropriate section in chapter ”4. Replacement Procedures”.

Chapter “5. Speciﬁcations” contains technical data for the ModulT disc brake.

Chapter “6. Tools” contains information about the Haldex ModulT Tool Kit, which is essential for carrying out much of the replacement procedure work described in this manual.

Chapter ”7. Fault Finding” should be used to help with the self diagnosis of any problem being experienced.

Finally Chapter “8. Components List and Exploded View” lists and shows what spare part components are available for the ModulT disc brake.

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ModulT Service Guide

1.1.1 Spare Parts

It is vital that only Haldex original spare parts are used during all service replacement activities.

The use of none Haldex original spare parts can affect the function, performance and/or lifetime of the parts.

The use of none Haldex original spare parts will immediately terminate any warranty of the disc brake unit.

1.1.1.1 Label description

A. Logo

B. OEM Part Number

C. A/M Part Number

D. Serial Number

There will be variants in S/N numbers containing 8 or 10 digits.

Brakes produced after 10-05-2014 will contain 10 digits.

Serial Number explanation:

Ch.no 1 2 3 4 5 *) 6 *) 7 8 9 10

Ex. 1 4 0 4 1 0 2 2 5 2

Comment Year Year Week Week

*) Ch.no 5 and 6 is the numbers that is added to the 10 digits alternative.

Haldex

number

A. Logo

B. OEM Part Number

C. A/M Part Number

D. Serial Number

Figure 104. Label description

Haldex

number

Serial

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ModulTService Guide

1.2 The Haldex ModulT

The Haldex ModulT is an air disc brake platform developed for the purpose of meeting increased customer demands on performance, robustness, service up-time and weight.

The ModulT superior design encompasses the following advantages:

Low weight;

Single tappet piston with similar clamping force distribution as Haldex twin tappet piston;

Simpliﬁed maintenance; boltless pad retainer and only two bolts in the complete brake;

Modular; the same piston and sliding function design used on multiple brake sizes;

Long service life; stainless sliding pins, PTFE coated steel bushings, and the mechanism bellows is folded inwards thus protected from external debris (stones/ blister etc.);

High efﬁciency; the use of double roller bearings for the mechanism lever keeps the hysteresis low and thus a high efﬁciency is achieved.

ModulT_053

Figure 1. The Haldex ModulT Disc Brake

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1.3 Functional Description

The ModulT is designed to provide high performance coupled with low weight, durability and a minimum number of wearing parts.

ModulT Service Guide

The ModulT enhances a ﬂoating monobloc caliper (C) and an integrated adjustment unit which compensates for brake pad wear.

The unit, which is actuated by the mechanism lever (A), presses the inner brake pad (B) against the disc, which then causes the caliper (C) to slide laterally, so that the outer brake pad (D) also comes in contact with the disc, see ﬁgure 2.

The caliper moves on slide pins (E), see ﬁgure 3. Where the disc brake also serves as a parking brake, the unit is actuated by a spring brake chamber (F).

ModulT_001

Figure 2. Functional description

ModulT_069

Figure 3. Slide pins and spring brake chamber

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1.3.1 This page left blank intentionally

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1.3.2 Technical Information DBT22LT

ModulT_107

The DBT22LT is a disc brake intended for a 430 mm disc and used for applications with dynamic axle loads up to 23K lbs (9 tons)*. 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 (9 tons)* › For wheel size 22.5 in

ModulT Service Guide

Figure 106. DBT22LT Inner side

› Max operation for

ce 8K ft-lbs (11 kN)

› Friction radius 6.8 in (173 mm) › Max brake cylinder str

oke 2.5 in (65 mm)

› Nominal brake ratio 15.4 : 1 › Mechanical efﬁciency > 93 % › Running clearance (min-max) 0.02 - 0.04 in

(0.7 - 1.1mm)

› W

eight of complete disc brake unit, including pads <

70 lbs (< 32 kg)

Disc:

› Exter

nal diameter of brake disc 16.9 in (430 mm)

› T

otal thickness when new 1.8 in (45 mm)

› Minimum permitted thickness 1.5 in (37 mm)

Pad:

› Total thickness 1.2 in (30 mm) › Backplate thickness 0.03 in (8.0 mm)

Figure 108. DBT19LT Top view

› Minimum friction material thickness 0.08 in (2.0 mm)

Options:

› Pad W

ear Indicator (PWI)

› > Pad Wear Indicator Sensor (PWIS) › > Pad W › Carrier hole patter

ear Sensor (PWS)

n (Standard and Wide)

* Can also be used with 20K/23K lbs (10 tons) axle loads dependant on application.

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Safety Precautions

2.1 General Information

This chapter comprehends the Safety Precautions that shall be read and followed before any Inspection/ Removal/Installation procedure described in this Service Guide is started.

This Service Guide is intended for the exclusive use of trained persons within the commercial vehicle industry and related work shops.

Three different alert levels are used through out this Service Guide: Warning, Important and Note.

Their differences are explained below:

A Warning message is always accompanied by a safety alert symbol.The safety alert symbol is used to alert about potential personal injury hazards. To avoid hazards, obey all safety messages that follow this symbol. Failure to observe this information can cause serious personal injury or death!

IMPORTANT! An important message is always accompanied by the signal word IMPORTANT! The Important sign means risk of damage to the brake! Failure to observe this information could result in damage to the whole brake or parts of it!

NOTE! A notiﬁcation message is always accompanied by the word NOTE! The Note sign is used to emphasize important information and is not to be regarded as hazard information.

2.2 Installation

The disc brake must not be installed or treated in such a way that exposes it to none 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.

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ModulT Service Guide

2.3 Adjustment of Control System/Valves

Failure to follow the instructions in this chapter may accelerate the wear to the brake pads and may cause damage/repeated damage to the disc brake, axle and/or wheel brake components.

2.3.1 Before entering the Vehicle into service

Prior to ﬁrst time use a vehicles disc brake operating systems must be checked and adjusted (if necessary) in accordance with the relevant brake calculations. Contact the vehicle manufacturer for relevant information.

2.3.2 Replacing Spare Parts

Always use spare parts that are approved for the vehicle, axle or disc brake. Following replacement of any essential components or spare parts in the disc brake operating system (such as brake valves or control units), the disc brake operating system must also be checked and adjusted (if necessary) in accordance with vehicle speciﬁcations.

2.3.3 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 in accordance with the legally applied braking calculations.

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, discs, tyres and wheel components.

Following replacement of any essential components or spare parts in the disc brake operating system (e.g. brake valves or control units), the disc brake operating system must also be checked and adjusted in accordance with the relevant braking calculations.

Failure to follow these instructions may cause damage/repeated damage to the disc brake, axle and/or wheel brake components.

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ModulTService Guide

2.4 Brake Chamber

Moisture/water ingress into the disc brake’s mechanism housing will potentially affect the function of the disc brake and as a result shorten its life.

Therefore, to prevent water ingress it is important that the disc brake chamber is of the correct design and that the seal between the brake chamber and disc brake mating surface is undamaged correctly in place.

It is also important for the disc brake’s function that the brake chamber housing is correctly ventilated.

As a minimum, the drain holes facing downwards must be open, see ﬁgure 4. Other drain plugs can remain in position in the brake chamber housing.

IMPORTANT! If all the drain plugs remain ﬁtted, the brake chamber and disc brake will not operate correctly!

ModulT_034

Figure 4. Brake chamber ventilation

2.5 Recycling

When replacing the disc brake or parts thereof, the components removed must be recycled/destroyed in compliance with applicable environmental legislation, regulations and provisions.

2.6 Cleaning

For the disc brake to function correctly it is important to ensure it is kept clean and that its normal movements are not restricted by mud, ice, snow, objects, etc. penetration resulting in malfunction/shortening of the service life of the disc brake.

Damage may cause direct brake failure or damp/dirt

IMPORTANT! It is important to take care when using chemicals and/or cleaning tools (e.g. knife, brush, etc). This to avoid damage or displacement of hoses, seals and other components.

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ModulT Service Guide

2.7 Surface nishing for Disc Brake

2.7.1 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 and/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 and it’s protection Plug, complete Brake Pads, the swept area of the disc, the disc brake mounting surfaces to axle/brake chamber and all bolted connections.

2.7.2 Shot-blasting

IMPORTANT! Failure to follow the instructions below could compromise safety and/or reduce the life of the disc brake and its components.

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.

NOTE! Do not forget to follow the recommendations of the brake chamber manufacturer.

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.

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ModulTService Guide

Initial and Final Procedures

3.1 General Information

The objective of this chapter is to give guidelines on how Initial and Final Procedures shall be performed in a standardised way.

Initial Procedure is a recurring procedure that have to be performed prior to the Inspection and/or Replacement procedures covered in this Service Guide.

Final Procedure is a recurring procedure that have to be performed after an Inspection and/or Replacement procedure covered in this Service Guide.

3.2 Initial Procedure

3.2.1 Lift up and support the vehicle axle

At least one of the vehicle´s axles shall be blocked to prevent involuntary movement of the vehicle!

The vehicle manufacturer´s safety precautions shall be followed when working on the vehicle!

Local safety precautions shall be complied!

On a ﬂat and even surface, block the wheels, see

e 5.

ﬁgur

Lift the axles and place on stands.

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ModulT_004

Figure 5. Block the wheels

ModulT Service Guide

If the disc brake is equipped with a parking brake chamber. Ensure that the brake system is depressurized and the spring brake chamber is fully disengaged and mechanically secured in the released position.

See the vehicle manufacturer´s instructions.

ModulT_055

Figure 6. Mechanically secure in the released position

3. Release the parking brake.

3.2.2 Removing the wheel

Take all necessary safety precautions before wheel removal! The vehicle manufacturer´s safety precautions shall also be followed!

Check the fr is higher than expected, tap the tire to remove any normal rest tension. If the wheel still does not rotate freely then consult chapter ”7. Fault Finding” to assist further.

2. Remove the wheel nuts followed by the wheel, see ﬁgure 7.

ee rolling resistance, if the resistance

ModulT_005

Figure 7. Remove the wheel

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ModulTService Guide

3.3 Inspection Procedures

3.3.1 General Information

The objective of this chapter is to give guidance on how inspection of the brake components shall be conducted. Always start by consulting the Inspection interval table below in chapter 3.3.2.

The Inspection interval table displays how frequent the different brake components shall be inspected and on which pages the check instructions are found.

The majority of the inspections demand that the wheel is removed from the vehicle. Before removing the wheel read chapter ”2. Safety Precautions” followed by “3.2 Initial Procedure” and “3.5 Final Procedure”.

3.3.2 Inspection intervals

The check intervals speciﬁed in the table below are maximum intervals. Depending on the vehicle application, type of driving, adjustment to the vehicle manufacturer’s service/inspection intervals etc, there may be a need for more frequent inspections.

C = Check

I = * = W

Inspect

heels Mounted

** = Wheels Removed

Braking Force Distribution C/I* C* C/I*

Brake Adjustment Function C*

Safety Check

Brake Pads I* I**

Brake Disc I* I**

Plugs and Protective Cups I**

Thrust Plate Guide Pins I**

Chamber Interface I**

Slide Pin bellow Seals I**

Adjustment Screw Bellow Seals

Slide Function I**

May be performed by vehicle manufacturer.

In accordance with industry recommended practices.

Before First

Vehicle Use

C* C**

Every 3 Months

Daily

I**

Every 12 Months

When System

Components

Are Replaced

ModulT Service

Manual Page

Reference

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3.3.3 Daily Safety Check

Contact the repair shop immediately if there is any sign of reduced performance or the brakes do not work properly!

1. Check that the brakes function properly before driving and that they work effectively and smoothly.

Check that the service and parking brake function

fective by trying to drive the vehicle with the

is ef service and parking brake applied.

3. Make sure you have good lighting conditions.

Inspect visible parts of the brake and its

4. components. Look for:

- Damage

- Collection of debris

- Corrosion

- Overheating signs

- Cracks and Corrosion in brake discs

- Unusual wear etc

ModulT Service Guide

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ModulTService Guide

ModulT_010

> 0.08 in (> 2 mm)

3.3.4 Inspections

3.3.4.1 Check Brake Pad wear

Wear respiratory protection in order to avoid inhaling particles which can be hazardous to your health! Brake pad wear produce dust which can cause lung damage!

NOTE! Step 1 in this procedure only indicate the pad wear of the outer pad! For a full examination do all steps.

Inspect the position of the V

1. (VWI), as located and shown in ﬁgure 14. This check can be done with either the wheel ﬁtted or removed.

The VWI provides an indication of outer pad wear condition, it does not provide an accurate measurement of pad wear on both pads.

To obtain and accurate wear measurement of both pads continue with the instructions which follow.

Remove the wheel accor

2. Procedure”.

Remove brake pads accor Replacement Pr

Look for unusual conditions like excessive

ocedures” on page 35.

corrosion and high heat cycles i.e. delamination, discoloration, etc. If found refer to chapter ”7 Fault Finding” for actions.

On both brake pads measur back plate (A) to wear surface (B) of the brake pad in four places, see ﬁgure 15. Minimum permitted lining thickness (friction material) is 0.08 in (2 mm).

Measur

e and compare differential brake pad thickness between the inner and outer brake pads. Up to 0.2 in (5 mm) difference is normal, if the difference is >0.2 in (> 5 mm) refer to chapter “7 Fault Finding” for further information.

Check the condition of the back plate (A), ie. rust

7. jacking.

Replace brake pads if they ar are expected to be so before the next inspection.

For replacement follow the instructions in chapter ”4.2 Replacement of Brake Pads”.

If the inspection is completed satisfactorily conclude by following chapters “4.2.3 Install Brake Pads” and “4.2.4 Final Procedure”.

NOTE! This brake disc inspection check procedure is only a general guide, refer to the vehicle manufacturers documentation for speciﬁc brake disc information and instruction.

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isual Wear Indicator

ding to chapter ”3.2 Initial

ding to chapter ”4

e the distance from

e worn out or if they

ModulT_009

Figure 14. Inspection of the Visual Wear Indicator

Figure 15. Measuring the pad wear condition

ModulT Service Guide

3.3.4.2 General Brake Pad clearance inspection

Wear respiratory protection in order to avoid inhaling particles which can be hazardous to your health! Brake pad wear produce dust which can cause lung damage!

NOTE! If using PWS/PWIS Use an 8mm socket with extension wherever the text ”Torx 55” is used in the instruction below.

Inspecting the clearance is only required for an approximation of the clearance between the brake disc and the brake pads.

The inspection can be carried out with or without the brake chamber ﬁtted.

This inspection is best performed after the wheel is removed and before the brake is de-adjusted. For this situation the steps 2 and 3 below can be skipped.

Read and follow chapters “3.2 Initial Pr

ocedure” and paragraph 4 from “4.2.2 Remove Brake Pads” prior to inspecting the pad clearance.

Adjust the r

eset shaft by inserting and manually

turning the Haldex special tool P/N 95232 (Torx

55) ”6 Tools” clockwise until it comes to a stop. Then de-adjust the reset shaft by turning it counterclockwise by 2 clicks.

Activate the brake until the T

orx 55 male no longer rotates because any excessive clearance has been removed by the adjustment function.

Insert two feeler gauges in between the caliper

4. and the outer brake pad to measur

e the clearance. Position the feeler gauges in the upper and lower part of the brake pad back plate so an average clearance is measured, see ﬁgure 16.

The normal running clearance is between 0.02 in

- 0.04 in (0.7 mm to 1.1 mm). If the measur

ement is outside of the normal running condition then refer to chapter ”7. Fault Finding” for further investigations.

ModulT_026

Figure 16. Correct location of the feeler gauges

6. Once the inspection is completed satisfactorily, conclude by reading and following chapters, paragraph 6 from “4.2.3 Install Brake Pads” and all from “4.2.4 Final Procedure”.

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3.3.4.3 Inspect Brake disc

Wear respiratory protection in order to avoid inhaling particles which can be hazardous to your health! Brake pad wear produce dust which can cause lung damage!

ModulTService Guide

1. Look for wear, damages and cracks, see ﬁgure

17. Also refer to the axle/vehicle manufacturer instructions. Cracks that enter the cooling ducts via the outer or inner radius are not permitted!

Acceptable crack length

< 75% of brake disc width

ModulT_011

Figure 17. Inspection of the Brake Disc

Unacceptable crack length

> 75% of brake disc width

Measur

e the thickness of the brake disc using a brake micrometer or slide caliper. If the brake disc has a wear ridge, the measurement can be performed using two spacers (B) (1/4” (5 mm) washer/spacers), see ﬁgure 18. Reduce the measured dimension by the total thickness of the two spacers (B).

Minimum permitted thickness of the brake disc is

1.5 in (37 mm).

The brake disc must be replaced if the wear limits have been exceeded.

ModulT_012

Figure 18. Measuring the Brake Disc thickness

NOTE! This brake disc inspection check procedure is only a general guide, refer to the vehicle manufacturers documentation for speciﬁc brake disc information and instruction.

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ModulT Service Guide

3.3.4.4 Inspect Plugs and Protective Cups

Wear respiratory protection in order to avoid inhaling particles which can be hazardous to your health! Brake pad wear produce dust which can cause lung damage!

IMPORTANT! Use a vacuum cleaner to clean surfaces. Do not use compressed air!

IMPORTANT! Failure to follow the instructions below could compromise safety and/or reduce the life of the Disc Brake and its components.

NOTE! If a PWS /PWIS is mounted read and follow chapter 4.4 Reset and Installation of PWS (Pad Wear Sensor) and PWIS

Read and follow chapter “3.2 Initial Pr

1. prior to inspecting the protective plugs and cups.

ocedure”

Remove dirt fr

Check for signs of excessive heat exposur

om surfaces if necessary.

discoloration, debris etc.

The following plugs and pr

otective cups shall be in

place and intact:

The reset shaft protection plug identiﬁed as (A) and caliper seal (B), see ﬁgure 103 and 19.

Protection plug B is never removed.

The two pr

otection cups for slide pin protection (C),

see ﬁgure 20.

6. Once the inspection is completed satisfactorily, conclude by reading and following chapter “3.5 Final Procedure”.

Figure 103. PWIS/PWS protection plug

ModulT_013

Figure 19. The two protection plugs

ModulT_014

Figure 20. The three protection cups

IMPORTANT! Never remove the protection plug (B) and never turn the special screw (D) on ﬁgures 19 and 20. If the protection plug (B) is removed and the Screw (D) is turned, it will void warranty and will compromise the life of the disc brake!

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ModulTService Guide

3.3.4.5 Inspect Thrust Plate Guide Pins

Wear respiratory protection in order to avoid inhaling particles which can be hazardous to your health! Brake pad wear produce dust which can cause lung damage!

IMPORTANT! Use a vacuum cleaner to clean surfaces. Do not use compressed air!

Read and follow chapter “3.2 Initial Pr

1. prior to inspecting the thrust plate guide pins.

Remove dirt fr

Inspect that the two thrust plate guide pins (E), see

3. ﬁgur

e 21, are in their correct position.

Inspect that the thrust plate with guide pins ar

om surfaces as necessary.

free to move without obstruction.

ocedure”

Once the inspection is completed satisfactorily conclude by reading and following chapter “3.4 Final Procedure”.

ModulT_015

Figure 21. The two thrust plate guide pins

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ModulT Service Guide

3.3.4.6 Inspect Actuation Interface

Wear respiratory protection in order to avoid inhaling particles which can be hazardous to your health! Brake pad wear produce dust which can cause lung damage!

IMPORTANT! It is important to take care when using chemicals and/or cleaning tools (e.g. knife, brush etc). This to avoid damage or displacement of hoses, seals and other components.

IMPORTANT! Use a vacuum cleaner to clean surfaces. Do not use compressed air

This inspection procedure covers both types of brake chambers; service and parking.

Read and follow chapter “3.2 Initial Pr prior to inspecting the actuation interface.

ocedure”

oughly clean around the mating surfaces of

Thor the brake chamber (A) and caliper (B) to ensure that dirt does not get into the mechanism area when removing the brake chamber. See ﬁgure 22.

If applicable ensur

e that the spring brake chamber

See the vehicle manufacturer´s instructions.

ModulT_028

Figure 22. The mating surfaces of the brake chamber and caliper

ModulT_055

Figure 6. Mechanically secure in the released position

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ModulTService Guide

Pressure from lines and components shall be released before opening them!

(F) is fully disengaged and mechanically secured in the released position.

e that the brake chamber is depressurized.

Ensur

5. Remove the two nuts (E) holding the brake

chamber. Remove the brake chamber (A/F) from the caliper (B), see ﬁgure 23.

6. With the brake chamber removed and secured,

the brake chamber actuation rod should protrude ~0.6 in (~15 mm) in its rest position, See ﬁgure

24.

Activate the service brake, the brake chamber actuation r

od should protrude ~ 3.15 in

(~80 mm).

Also check that the actuation r

od extends

perpendicular to the external seal ﬂange.

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Figure 23. Removal of brake chamber items

Inspect thr

ough the aperture in the brake chamber attachment ﬂange for moisture/ corrosion, see ﬁgure 25. It’s important to look inside the aperture and not just on the surface.

If corrosion is seen then further inspection is necessary. If concluded that water has ingressed causing internal corrosion/damages to the mechanism then replace the caliper complete to avoid operating problems.

If action is required see chapter ”4.9 Replacement of Disc Brake” on page 71.

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Figure 24. The actuation rod

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Figure 25. The brake chamber aperture

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10. Inspect that the bellows are complete and not damaged by looking around and down the push rod shaft. Also look for signs of water or corrosion which may be a sign that the bellows are damaged.

Inspect that the exter

11.

nal seal ﬂange (A) is correctly

seated in place, intact and undamaged.

12. Once the inspection is completed satisfactorily, conclude by reading and following chapters “4.5.3 Install Brake Chamber” and “4.5.4 Final Procedure”.

ModulT Service Guide

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Figure 26. Internal view of a brake chamber

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3.3.4.7 Inspect Slide Pin Bellows

Wear respiratory protection in order to avoid inhaling particles which can be hazardous to your health! Brake pad wear produce dust which can cause lung damage!

IMPORTANT! It is important to take care when using chemicals and/or cleaning tools (e.g. knife, brush etc). This to avoid damage or displacement of hoses, seals and other components.

IMPORTANT! Use a vacuum cleaner to clean surfaces. Do not use compressed air

Read and follow chapters “3.2 Initial Pr

ocedure” and “4.2.2 Remove Brake Pads” prior to inspecting the slide pin bellows.

Inspect the Leading slide pin bellows (A) and the

railing slide pin bellows (B), see ﬁgure 27. Look all

T around the bellows for damage signs than could have been caused by debris, stones or overheating.

3. If the bellows are damaged then they need replacing. For instructions on how to replace the bellows read and follow ”4.7 Replacement of Slide Function Assembly”.

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Figure 27. Inspecting the slide pin bellows

Once the inspection is completed satisfactorily conclude by reading and following chapters “4.2.3 Install Brake Pads” and “4.2.4 Final Procedure”.

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ModulT Service Guide

3.3.4.8 Inspect Thrust Plate Bellows

Wear respiratory protection in order to avoid inhaling particles which can be hazardous to your health! Brake pad wear produce dust which can cause lung damage!

IMPORTANT! It is important to take care when using chemicals and/or cleaning tools (e.g. knife, brush etc). This to avoid damage or displacement of hoses, seals and other components.

IMPORTANT! Use a vacuum cleaner to clean surfaces. Do not use compressed air!

Read and follow chapters “3.2 Initial Pr

1. and “4.2.2 Remove Brake Pads”, prior to checking the thrust plate bellows.

ocedure”

IMPORTANT! Never use an impact wrench or suchlike to turn the reset shaft. This may damage the disc brakes mechanism! Torque is 15K ft-lbs (20 Nm) max.

Note! Do not over adjust/extend the thrust plate whilst carrying out the inspection. Over adjustment/ extension will cause the thrust plate to disengage from the thrust plate and if done unintentionally may cause damage to the thrust plate bellows! Min distance between the caliper and thrust plate is 2.4 in (60 mm).

NOTE! If using PWS/PWIS Use an 8mm socket with extension wherever the text ”Torx 55” is used in the instruction below.

Using Haldex special tool P/N95232 ”6 T

2. (Torx 55), manually turn the reset shaft clockwise to adjust the brake so that the thrust plate (A) is

ools”

2.4 in (60 mm)

extended and the bellows can be viewed. Stop when the distance between the inner pad face of the thrust plate and outer pad face on the caliper is

2.4 in (60 mm), see ﬁgure 28.

NOTE! Further turning of the reset shaft will result in thrust plate becoming disengaged.

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Figure 28. Max extension to check the thrust plate bellows

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3. Inspect the thrust plate bellows, see ﬁgure 29. Look all around the bellows for damage signs that could have been caused by debris, stones or overheating.

If the bellow is damaged then it needs r

eplacing. For instructions on how to replace the bellows read and follow ”4.6 Replacement of Thrust Plate Bellows”.

5. If OK then manually de-adjust the thrust plate by turning the Torx 55/reset shaft counter-clockwise, until the position required to reﬁt the brake pads.

Once the inspection is completed satisfactorily conclude by reading and following chapters “4.2.3 Install Brake Pads” and “4.2.4 Final Procedure”.

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Figure 29. Inspect the thrust plate bellows

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3.3.4.9 Inspect slide Function

Wear respiratory protection in order to avoid inhaling particles which can be hazardous to your health! Brake pad wear produce dust which can cause lung damage!

IMPORTANT! It is important to take care when using chemicals and/or cleaning tools (e.g. knife, brush etc). This to avoid damage or displacement of hoses, seals and other components.

IMPORTANT! Use a vacuum cleaner to clean surfaces. Do not use compressed air!

Read and follow chapters “3.2 Initial Pr

ocedure” and “4.2.2 Remove Brake Pads” prior to inspecting the slide function.

Once the brake pads ar

e removed, move the caliper by hand back and forth to check its movement, see ﬁgure 30. The caliper must be free to slide on the leading and trailing slide pins.

If the movement is felt to be obstructed in some way then it is necessary to determine the r

oot cause, see chapter ”3.3.4.9.1 Measure slide function movement” for assistance in this.

If the r

oot cause investigation concludes that the

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Figure 30. Caliper free movement

slide function needs replacing then follow chapter “4.7 Replacement of Slide Function Assembly”.

Once the inspection is completed satisfactorily

, conclude by reading and following chapters “4.2.3 Install Brake Pads” and “4.2.4 Final Procedure”.

IMPORTANT! Obstruction of the slide function can cause operational problems like hot brakes and uneven brake pad wear.

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3.3.4.9.1 Measure Slide Function Movement

1. Read and follow chapter 3.2.1 Lift up and support the vehicle axle.

Read and follow chapter 3.2.2 Removing the wheel.

Read and follow chapter 4.2.2 Remove Brake Pads.

Measurement:

Push by hand the brake caliper as far as possible in the arr

ow direction, see ﬁgure 90.

2. Place the dial indicator on the carrier (position A) and clean the measuring point (B) with a cloth and place the dial indicator for measurement in position B, see ﬁgure 91.

Figure 90. Brake caliper inner position

Figure 91. Dial indicator on caliper

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3. Tilt the caliper as in ﬁgure 92 black arrows (No high force is needed).

Put

the dial indicator to zero.

5. Now tilt the caliper as in ﬁgure 92 red arrows and read the measured play on the dial indicator.

Measurement speciﬁcations:

If the bushing play measures over 0.08 in (2 mm); the bushing needs to be replaced. Chapter ”4.7

Replacement of Slide Function Assembly”.

The trailing bushing is made by a soft composite material. If a metallic sound appears from the trailing bushing it must be replaced, see ﬁgure 93 and 94.

ModulT Service Guide

Figure 92. Caliper measured play

A = Leading bushing

B = Trailing bushing

Figure 93. Caliper bushing

LH RH

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Figure 94. Leading Trailing Bushing

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3.4 Function Test

3.4.1 Test of Adjustment Unit

The function test can be carried out with the wheel installed or removed.

1. Check that the wheel/hub can rotate freely. If it does not then ﬁrst tap to remove any rest tension. If the wheel still does not rotate freely then consult chapter ”7. Fault Finding” to assist further.

IMPORTANT! Use a vacuum cleaner to clean surfaces. Do not use compressed air!

IMPORTANT! It is important to take care when using chemicals and/or cleaning tools (e.g. knife, brush, etc). This to avoid damage or displacement of hoses, seals and other components.

IMPORTANT! Make sure that dirt and impurities do not enter the opening for the reset shaft!

IMPORTANT! Use recommended tools only!

NOTE! The Torx 55 and the Thrust plate must be allowed to move unhindered!

NOTE! If using a PWS/PWIS read chapter 4.4 about the function.

NOTE! If using PWS/PWIS Use an 8mm socket with extension wherever the text ”Torx 55” is used in the instruction below.

IMPORTANT! Never use an impact wrench or similar to turn the reset shaft. This may damage internal parts of the mechanism! Torque is 15K ft-lbs (20 Nm) max.

Remove the r

eset shaft protection plug (A), see ﬁgure 8. (PWS / PWIS remove the black rubber plug on the sensor.)

Using Haldex special tool P/N95232 (T

3. Tools”, de-adjust the brake by turning the reset

orx 55) ”6

shaft counter-clockwise by 4 clicks, or till the end stop, see (B) ﬁgure 8. A distinct clicking sound shall be heard and felt when de-adjusting.

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Figure 8. De-adjustment via the reset shaft

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ModulT Service Guide

IMPORTANT! When reaching the end stop position of de-adjustment, never tighten and leave. Leaving the reset shaft tightened in the de-adjust position could stop the adjustment function from working! After reaching the end stop position always then adjust by turning the reset shaft clockwise 90 degrees, thus activating the adjustment function.

Leave the T

Actuate the brakes 5 times by pr

5. the vehicles brake pedal through its full stroke. See ﬁgure 9. If no brake chamber is ﬁtted then actuate the brake chamber lever manually with a suitable tool.

orx 55 in position in the reset shaft.

essing and releasing

orx 55 must rotate clockwise only on each

The T actuation, showing that the automatic adjustment function is working.

If the T

orx 55 rotates back and forth or not at all, then the adjustment function is not working correctly.

8. To check further, manually adjust the reset shaft by turning the Torx 55 clockwise by 360 degrees, and then counter-clockwise by 180 degrees to ensure the adjuster is not jammed at the full de-adjust position.

Also note that once the excessive clearance is taken

9. up by the adjuster the T

orx 55 will naturally stop rotating. If in doubt, turn the Torx 55 counterclockwise by 180 degrees and then press the brake pedal again to check.

If the T

10.

orx 55 still rotates back and forth during actuation then the adjustment function is defective and the caliper must be replaced.

See chapter ”4.9 Replacement of Disc Brake”.

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Figure 9. Brake actuation

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ModulTService Guide

“CLICK”

3.5 Final Procedure

IMPORTANT! Use a vacuum cleaner to clean surfaces. Do not use compressed air!

IMPORTANT! It is important to take care when using chemicals and/or cleaning tools (e.g. knife, brush, etc). This to avoid damage or displacement of hoses, seals and other components.

IMPORTANT! Make sure that dirt and impurities do not enter the opening for the reset shaft!

NOTE! If using a PWS/PWIS read chapter 4.4 about the function.

NOTE! If using PWS/PWIS Use an 8mm socket with extension wherever the text ”Torx 55” is used in the instruction below.

3.5.1 Final brake adjustment

1. Using Haldex special tool P/N95232 (Torx 55) ”6 Tools”, manually adjust the brake by turning the reset shaft clockwise until the pads touch the disc and you feel an end stop.

Then tur

n the reset shaft counter-clockwise by 2

clicks, see ﬁgure 9.1.

This procedure is the initial brake pad setting.

3. 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!

See Figure 10.

3.5.2 Mounting of the wheel

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.

Mount the wheel, see Figur

e 11.

Figure 9.1. Initial brake pad setting

Figure 10. Correct ﬁtment of the protective plug

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Figure 11. Mount the wheel

3.5.3 Lowering of the vehicle axle

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

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Figure 12. Mechanically secure in the active position

IMPORTANT! Make sure that there is sufﬁcient air in the system [min. 90 psi (6 bar)].

Activate the parking brake if ﬁtted with a spring brake chamber

Lift the axles so that the stands can be r

efully lower the vehicle to the ground.

Car

Remove the wheel blocks, see Figur

emoved.

e 13.

Figure 13. Remove the stops

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Replacement Procedures

4.1 General Information

The objective of this chapter is to give instruction and guidance on how the disc brake and/or its components shall be replaced. All the replacement procedures in this chapter require that the wheel is taken off to enable the replacement work to be carried out.

4.2 Replacement of Brake Pads

4.2.1 Initial Procedure

Read and follow chapter ”3.2 Initial Procedure” prior to removing the brake pads.

4.2.2 Remove Brake Pads

Wear respiratory protection in order to avoid inhaling particles which can be hazardous to your health! Brake pad wear produce dust which can cause lung damage!

IMPORTANT! Use a vacuum cleaner to clean surfaces. Do not use compressed air!

IMPORTANT! It is important to take care when using chemicals and/or cleaning tools (e.g. knife, brush etc). This to avoid damage or displacement of hoses, seals and other components

NOTE! If using a PWS/PWIS read chapter 4.4 about the function.

If necessary r obstruction.

emove dirt, dust and other possible

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ModulT Service Guide

IMPORTANT! Only use Haldex special tools where speciﬁed!

IMPORTANT! Never use an impact wrench or suchlike to turn the reset shaft. This will damage internal parts of the mechanism! Torque is 15 ft-lbs (20 Nm) max.

NOTE! The thrust plate must be fully retracted to be able to fit new pads.

NOTE! If using a PWI read chapter 4.3 about the function.

NOTE! If using PWS/PWIS Use an 8mm socket with extension wherever the text ”Torx 55” is used in the instruction below.

Remove the r

eset shaft protection plug (1). See

ﬁgure 31.

Using Haldex special tool P/N 95232 (T

orx 55) ”6 Tools”, manually turn the reset shaft counterclockwise to de-adjust the brake so that the thrust plate fully retracts to its inner position (2).

A clicking sound shall be heard and felt when de-adjusting.

The stop at fully retracted inner thrust plate position must be distinct, but do not exceed 15 ft-lbs (20 Nm) in torque or leave it tightened in this position.

Sudden release of tensioned springs can cause injury!

Do not actuate the brake when changing the brake pads!

Max 15 ft-lbs (20 Nm)

Figure 31. De-adjust the thrust plate via the reset shaft

Also, ensure the air brake system is pressurized during the replacement procedure, minimum 60 psi (4 bar)! If the pressure drops below 60 psi (4 bar) the park brake will be acutated.

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IMPORTANT! Always ensure the pad retainer spring bracket is fully held down whilst levering out the pad retainer

Remove the pad r

etainer by ﬁrst pushing and holding down the spring bracket (A), see ﬁgure 32. Whilst the spring bracket (A) is held down, slide out and remove the pad retainer (B). A tool can be used to help slide out the pad retainer if unable to do so be hand. Continue to remove the two pad springs (C).

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Figure 32. Removal of brake pad components

NOTE!

When replacing the brake pads you shall use the new parts included in the kit. Dispose the old parts.

NOTE!

There are two versions of the pad springs, model A and model B. It is important to mount these with the

right brake pads.

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ModulT Service Guide

IMPORTANT! Always remove the outer brake pad ﬁrst! You cannot directly pull out the inner brake pad with the outer still in place as the inner brake pad is located to the thrust plate on two points.

Remove the brake pads; always r

emove the outer brake pad (A) ﬁrst, followed by the inner brake pad (B). See ﬁgure 33.

This is because the inner brake pad back plate locates on two holes which mate to the thrust plate, therefore you cannot directly pull out the inner brake pad with the outer brake pad still being in place.

Once the outer brake pad is removed the caliper can be slid across to allow for the inner brake pad to be removed.

Remove the pad r

etainer spring bracket (C).

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Figure 33. Removal of brake pads

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4.2.3 Install Brake Pads

1. Make sure that the brake is fully de-adjusted before ﬁtting new brake pads.

Check that the contact surfaces on the carrier

, caliper and thrust plate are free from dirt and corrosion. Clean if necessary.

IMPORTANT! The inner brake pad must always be installed ﬁrst!

IMPORTANT! Ensure that the friction material faces the brake disc!

First install the inner brake pad (B) in the caliper

3. note that the inner brake pad locates onto the thrust plate on two points, see ﬁgure 34. Then ﬁt the outer brake pad (A).

Check that the contact surfaces on the pad r

etainer spring bracket are free from dirt and corrosion. Clean if necessary.

Install the new spring bracket (C) into the caliper

5. and ensur

e it is seated in position correctly.

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Figure 34. Install the brake pads

NOTE!

When replacing the brake pads you shall use the new parts included in the kit. Dispose the old parts.

NOTE!

There are two versions of the pad springs, model A and model B. It is important to mount these with the

right brake pads.

2016

6. Fit the new pad springs (A) and the pad retainer (B).

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, ﬁnally slide the pad retainer under the caliper latch until the spring bracket pops into its locking position, see ﬁgure 35.

If necessary, use a tool to help push the pad retainer into position.

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ModulT Service Guide

Upon assembly, ensure the pad retainer spring bracket is in its correct locking position.

4.2.4 Final Procedure

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Figure 35. Installation brake pad components

To conclude this procedure read and follow chapters:

”3.4 Function T

est” to ensure that the disc brake is working

correctly;

2. ”3.5 Final Procedure”.

If using PWS/PWIS r

ead and follow chapter ”4.4 Reset and

installation of PWS and PWIS”

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ModulTService Guide

4.3 Replacement of PWI

4.3.1 Install Brake Pads and PWI (Pad Wear Indicator)

1. Make sure that the brake is fully de-adjusted before

ﬁtting new brake pads.

Check that the contact surfaces on the carrier

, caliper and thrust plate are free from dirt and corrosion. Clean if necessary.

IMPORTANT! The inner brake pad must always be installed ﬁrst!

IMPORTANT! Ensure that the friction material faces the brake disc!

First install the inner brake pad (B) in the caliper note that the inner brake pad locates onto the thrust plate on two points, see ﬁgure 34. Then ﬁt the outer brake pad (A).

Fit PWI connectors (B and D) in place wher

e appropriate in the (A) inner pad and (C) outer pad. See ﬁgure 109.

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Figure 34. Install the brake pads

Note! The PWI connectors (B and D) must be installed in the correct direction to ﬁt the pads (A and C) and to obtain the correct function. Surface (B) on the same side as the brake pad material.

Figure 109. PWI connector ﬁtting

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5. Check that the contact surfaces on the pad retainer

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spring bracket are free from dirt and corrosion. Clean if necessary.

Install a new spring bracket (C) into the caliper and

e it is seated in position correctly.

ensur

7. The PWI cable (D) for the outer brake pad (C) must be positioned correctly. Cable going out and over the Pad spring to avoid that the cable will be damaged. See ﬁgure 110.

ModulT Service Guide

Figure 110. PWI Cable ﬁtting

NOTE!

When replacing the brake pads you shall use the new parts included in the kit. Dispose the old parts.

NOTE!

This is because there are two versions of the pad springs, model A and model B.

It is important to mount these with the right brake pads.

Upon assembly, ensure the pad retainer spring bracket is in its correct locking position

Fit the new pad springs (A) and the pad r

etainer (B). 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, ﬁnally slide the pad retainer under the caliper latch until the spring bracket pops into its locking position, see ﬁgure 35. Fit the PWI cable to the retainer so that the cable will not be damaged, ﬁt the cover plate.

If necessary, use a tool to help push the pad retainer into position.

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Figure 35. Installation brake pad components

See ﬁgure 111.

9. To conclude this procedure read and follow chapter

“4.2.4 Final Procedure .

Figure 111. PWI cabel to the retainer

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4.4 PWS Pad Wear Sensor / PWIS Pad Wear Indicator Sensor

4.4.1 Function description:

PWS (Pad Wear Sensor = Black housing)

PWIS (Pad Wear Indicator Sensor = Gray housing)

PWS is a continuous wear sensor that monitors pad wear and provides continuous data to the vehicle system. PWIS is a black and white sensor that will give the vehicle system a signal when the brake pads reach their wear limits and need to be replaced.

The PWS /PWIS should always be manually set to its start position when changing to new brake pads, to be able to compensate for disc wear during each pad change.

There is no mechanical stop in either sensor, so the input shaft (C) can rotate freely without any risk of damage to the internal mechanism parts. The input shaft (C) can be turned both clockwise or counterclockwise to ﬁnd the start position. The planetary gears inside the sensor mechanism allow 13 revolutions of the input shaft (C) between the start positions.

ModulT Service Guide

Figure 96. PWS/PWIS sensor

To locate the sensors start position, two “click” sounds within a half turn can be heard when rotating the shaft. The start position is located anywhere between the “clicks”.

IMPORTANT! Never use an impact wrench to turn the reset shaft. This will damage internal parts of the mechanism! Torque is 15 ft-lbs (20 Nm) max.

To manually adjust or de-adjust the brake for changing the Pads. Remove the protection plug (A) and use a standard 8 mm socket tool (B) (see ﬁgure 96).

One M8 bolt fastens the sensor to the brake for easy mounting.

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4.4.2 Replacement of Brake Pads with PWS/PWIS installed

1. Replacement of Brake Pads

Final pr

Remove PWS/PWIS

Set PWS/PWIS start position

Install PWS/PWIS after Set Start Position

IMPORTANT! Use a vacuum cleaner to clean surfaces. Do not use compressed air!

IMPORTANT! It is important to take care when using chemicals and/or cleaning tools (e.g. knife, brush, etc). This to avoid damage or displacement of hoses, seals and other components.

ocedure

4.4.2.1 Replacement of Brake Pads

Read and follow chapter ”4 Replacement Procedures

4.4.2.2 Final Procedure

Read and follow chapter ”3.5 Final Procedure”

4.4.2.3 Remove PWS/PWIS

IMPORTANT! Never use an impact wrench or suchlike to turn the reset shaft. This will damage internal parts of the mechanism! Torque is 15 ft-lbs (20 Nm) max.

1. If necessary remove dirt, dust and other possible obstruction.

Unscr

ew the M8 Bolt (C) and pull out the PWS/PWIS (D) from the caliper (see ﬁgure 97).

Figure 97. Remove PWS/PWIS

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ModulT Service Guide

4.4.2.4 Set PWS/PWIS Start Position

IMPORTANT! There will be 13 revolutions between start positions, then it will be two ”clicks” within a half revolution. Between these clicks is the sensors Start Position.

1. Turn the input shaft clockwise until you hear two ”clicks” (see ﬁgure 98). Note that it may take up to 13 full rotations of the input shaft before the clicks are reached.

Figure 98. PWI/PWIS Start position 1

2. Then turn counter-clockwise one ”click” (see ﬁgure

98). Anywhere between these clicks is the PWS/PWIS Start Position.

4.4.2.5 Install PWS/PWIS

1. Clean around the position of the sensor with a cloth (see ﬁgure 99).

Figure 98. Start Position 2

Figure 99. PWS/PWIS Cleaning position

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ModulTService Guide

2. With a ﬁnger smear a thin layer of general purpose grease around the two o-rings on the Sensors (see ﬁgure 100).

Align the hole in the clip with the M8 hole in

3. the caliper then push the sensor with the corr position into the caliper without changing the start position of the sensor.

(see ﬁgure 101).

To help ﬁtting the sensor correctly into the reset shaft, without changing the sensors start position, an 8mm socket with extension can be used. Use the tool to help guide the sensor into place and rotate the socket slightly to get the Input Shaft in position in the reset shaft. (see ﬁgure 102)

ect

Figure 100. PWI/PWIS grease o-rings

Figure 101. PWI/PWIS position into the caliper

Tighten the Bolt 18 ft-lbs (24 Nm) . Do not over tighten or else you may damage the PWI/PWIS sensor.

Fit the reset shaft protective plug (A) into the Sensor, ensure it is pushed fully into its correct sealing position (see ﬁgure 103). Failure to do so may compromise the life of the brake.

2016

Figure 102. PWI/PWIS position into the caliper with 8mm socket

Figure 103. PWIS/PWS protection plug

ModulT Service Guide

4.5 Replacement of Brake Chamber

4.5.1 Initial Procedure

Read and follow chapter ”3.2 Initial Procedure” prior to removing the spring brake chamber.

4.5.2 Remove Brake Chamber

Wear respiratory protection in order to avoid inhaling particles which can be hazardous to your health! Brake pad wear produce dust which can cause lung damage!

IMPORTANT! Use a vacuum cleaner to clean surfaces. Do not use compressed air!

IMPORTANT! It is important to take care when using chemicals and/or cleaning tools (e.g. knife, brush etc). This to avoid damage or displacement of hoses, seals and other components.

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. See ﬁgure 36.

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Figure 36. The mating surfaces of the brake chamber and caliper

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ModulTService Guide

If the disc brake is equipped with a parking brake chamber, ensure that the: – brake system is depressurized. – spring brake chamber is fully disengaged and mechanically secured in the released position. See the vehicle manufacturer’s instructions.

Figure 6. Mechanically secure in the released position

Pressure from lines and components shall be released before opening them!

2. If applicable ensure that the spring brake chamber (F) is fully disengaged and mechanically secured in the released position. See ﬁgure 37.

e that the brake chamber (A) is depressurized.

Ensur

Mark and r

emove the hose connections of the service brake (C) and if applicable the parking brake (D).

Remove the two nuts (E) holding the brake chamber

. Remove the brake chamber (A) from the

caliper (B).

6. Once the brake chamber is removed it is good practice and highly recommended to read and follow chapter “3.3.3.8 Check Actuation Interface”.

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Figure 37. Removal of brake chamber items

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ModulT Service Guide

4.5.3 Install Brake Chamber

1. Check that 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.

Prior to ﬁtting the brake chamber it is good

2. practice and highly r and follow chapter “3.3.3.8 Check Actuation Interface”.

IMPORTANT! It is important to take care when using chemicals and/or cleaning tools (e.g. knife, brush, etc). This to avoid damage or displacement of hoses, seals and other components.

Check that the surface of the caliper that mates

3. with the brake chamber is fr and corrosion. Do the same check on the brake chambers mating face (A) and seal. See ﬁgure 38.

ecommended to read

ee from dirt, moisture

Ensure the brake chamber seal is in the correct position and not damaged.

Put a knob of general purpose gr

ease in the ball cup of the brake chamber lever. Do not overﬁll the cup or let grease fall inside the brake.

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Figure 38. Pre-brake chamber mounting activity

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ModulTService Guide

Fit the new brake chamber (A) to the caliper (B)

5. with nuts (E), see ﬁgur ﬁrst before torque tightening to ensure the brake chamber seats parallel.

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

e 39. Screw the nuts home

IMPORTANT! Do not mix up the hoses!

Fit the brake chamber hose connection of the service

6. brake (C) and if applicable the parking brake (D). If ﬁtting both hoses, ensure connections (C) and (D) are the correct way around. See ﬁgure 39.

ModulT_033

Figure 39. Installation of brake chamber items

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ModulT Service Guide

7. Remove the ventilation drain plug that faces downwar ﬁgure 40. Also from the spring brake chamber if applicable.

IMPORTANT! Apply air to the parking brake. Make sure that there is sufﬁcient air in the system minimum 90 psi (6 bar).

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).

ds from the brake chamber housing, see

ModulT_034

Figure 40. Remove the ventilation drain plug

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.

4.5.4 Final Procedure

To conclude this procedure read and follow chapters:

1. ”3.4 Function Test” to ensure that the disc brake is working correctly;

”3.5 Final Pr

ocedure”.

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ModulTService Guide

4.6 Replacement of Thrust Plate Bellows

4.6.1 Initial Procedure

Read and follow the chapters below prior to removing the thrust plate bellows:

1. ”3.2 Initial Procedure”;

”4.2.2 Remove Brake Pads”;

”4.5.2 Remove Brake Chamber”;

“4.9.2 Remove Disc Brake”.

4.6.2 Remove Thrust Plate Bellows

1. Fasten the disc brake securely in a vise with soft jaws, see ﬁgure 41 for clamping arrangement. Ensure that the jaws of the vice do not damage the disc brake.

2016

ModulT_080

Figure 41. Clamping arrangement for replacing thrust plate bellows

ModulT Service Guide

NOTE! If using PWS/PWIS read chapter 4.4 about functions

NOTE! If using PWS/PWIS Use an 8mm socket with extension wherever the text ”Torx 55” is used in the instruction below.

Using Haldex special tool P/N 95232 (T

2. Tools”, 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 thrust plate, see ﬁgure 42.

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).

Be careful when removing the thrust plate not to damage its internal threads or the external threads on the thrust plate.

orx 55) ”6

52mm

3. 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

ModulT_035

Figure 42. Extract the thrust plate

damaging the sealing surfaces could cause water penetration leakage or seal corrosion upon re-assembly!

4.6.3 Cleaning

IMPORTANT! Use a vacuum cleaner to clean surfaces. Do not use compressed air!

IMPORTANT! It is important to take care when using chemicals and/or cleaning tools (e.g. knife, brush, etc). This to avoid damage or displacement of hoses, seals and other components.

IMPORTANT! Make sure that dirt and impurities do not enter the opening for the thrust plate!

Clean the thrust plate, the thrust plate and the thrust plate bellows sealing surfaces in the caliper. Ensure the parts are free from dirt, dust, debris, moisture and corrosion.

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ModulTService Guide

4.6.4 Install Thrust Plate Bellows

1. Fasten the thrust plate in a vise with soft jaws,

see ﬁgure 43 for the clamping arrangement. Do not over tighten or damage the thrust plate whilst clamping!

Clean the inter

nal threaded surface of the thrust

plate.

Ensur

e that the contact surfaces between the thrust plate and the bellows are clean and free from dirt, moisture and corrosion.

IMPORTANT! Only use Haldex special tools where speciﬁed!

4. By hand, using Haldex special tool P/N 95224 (C) ”6 Tools”, ﬁrmly press the thrust plate bellows (A) into position on the thrust plate (B), see ﬁgure 44.

Check that the bellows is correctly seated in position on the thrust plate.

ModulT_067

Figure 43. Clamping arrangement for thrust plate

Clean the exter

nal threaded surface of the thrust plate. Ensure the parts are free from dirt, dust, debris, moisture and corrosion.

Apply the gr

ease supplied with the spare parts kit, to the internal thread of the thrust plate and the external thread of the thrust plate.

7. Remove the thrust plate from the vise.

ModulT_037

Figure 44. Fitting the thrust plate bellows

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ModulT Service Guide

IMPORTANT! Do not cross thread the thrust plate and the thrust plate!

NOTE! If using a PWI read chapter 4.3 about the function.

NOTE! If using PWS/PWIS read chapter 4.4 about functions

NOTE! If using PWS/PWIS Use an 8mm socket with extension wherever the text ”Torx 55” is used in the instruction below.

8. By hand, hold the thrust plate in position against the thrust plate. Insert Haldex special tool P/N 95232 (Torx 55) ”6 Tools” into the reset shaft and carefully turn counter-clockwise, as the thrust plate turns, carefully engage the thrust plate threads onto the thrust plate.

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 counter-clockwise.

See ﬁgure 45.

Shortly after the thr

eads are engaged ensure that the two thrust plate guide pins correctly locate in their caliper holes.

10.

Continue to r

etract the thrust plate until the dimension between the thrust plate inner pad face and the caliper outer pad face is 2.7 in (70 mm), as per ﬁgure 45.

2.7 in (70 mm)

ModulT_038

Figure 45. Loading the thrust plate

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ModulTService Guide

IMPORTANT! Ensure that the bellows is correctly seated and undamaged. Failure to do so may compromise the life of the disc brake.

Assemble Haldex special tool .P/N 95225 (F) and

11. P/N 95226 (G) ”6 T special tools into the caliper end of the thrust plate bellows. See ﬁgure 46.

By hand, ﬁrmly pr

12. equal and parallel force so that the thrust plate bellows is pressed into position within the caliper.

ools”, load the assembled

ess on the special tool with

13.

The special tool can be r

emoved, rotated, and then reapplied to aid the equal and parallel bellows seating.

14.

Remove the special tool. Check that the bellows is

ectly seated all around within the caliper, see

corr ﬁgure 47.

Also, re-check the bellows is seated correctly on the thrust plate, see previous ﬁgure 44.

Failure to seat the bellows correctly will compromise the life of the brake!

15. Retract the thrust plate fully to its inner position by manually turning the reset shaft counterclockwise. A clicking sound shall be heard and felt when retracting. The stop at fully retracted inner thrust plate position must be distinct, but do not exceed 15 ft-lbs (20 Nm) in torque or leave it tightened in this position.

Figure 46. Pressing in the thrust plate bellows

ModulT_092

Figure 47. Adjustment screw bellows seated OK / Not OK.

4.6.5 Final Procedure

To conclude this procedure read and follow chapters:

“4.9.3 Install Disc Brake”;

“4.2.3 Install Brake Pads“;

“4.5.3 Install Brake Chamber”;

”3.4 Function Test” to ensure that the disc brake is working correctly;

”3.5 Final Pr

2016

ocedure”.

ModulT Service Guide

4.7 Replacement of Slide Function Assembly

4.7.1 Initial Procedure

Read and follow the chapters below prior to removing the slide function assembly:

”3.2 Initial Pr

”4.2.2 Remove Brake Pads”;

”4.5.2 Remove Brake Chamber”;

“4.9.2 Remove Disc Brake”.

4.7.2 Remove Slide Function Assembly

IMPORTANT! Where speciﬁed only use Haldex ModulT Tool Kit!

1. Fasten the caliper securely in a vise with soft jaws, see ﬁgure 48 for clamping arrangement. Ensure that the jaws of the vise do not damage the caliper.

ocedure”;

ModulT_039

Figure 48. Clamping arrangement for replacing the slide function assembly

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ModulTService Guide

2. Use a small hammer and chisel to remove the leading and trailing protective cups (A), see ﬁgure

49. The protective cups are not to be re-used.

ModulT_040

Figure 49. Remove slide protection cups .

Using 3/4” long drive 14 mm hexagon tool

3. r

emove the two bolts (B), see ﬁgure 50. The bolts

are not to be re-used.

ModulT_061

Figure 50. Remove the slide pin bolts

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ModulT Service Guide

4. 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, see ﬁgure

51.

ModulT_041

Figure 51. Remove the carrier

IMPORTANT! Be careful not to damage the slide pin bellows sealing surfaces in the caliper!

5. By hand push out and remove the leading slide pin (C) and the trailing slide pin (D), see ﬁgure 52.

ModulT_062

Figure 52. Remove the slide pins

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ModulTService Guide

6. By hand, carefully remove the two slide pin bellows (E), see ﬁgure 53. 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.

Car

efully follow steps 8 and 9 below to remove the two leading bearings (F) and the spacer (G) and trailing composite bushing (H), see ﬁgure 54.

ModulT_063

Figure 53. Remove the silde pin bellows.

ModulT_064

Figure 54. Remove the slide bearings and composite side bushing

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ModulT Service Guide

IMPORTANT! To secure correct function: Verify that the rotating bearing surface on (L) is facing towards the ﬂange on (K).

IMPORTANT! Only use Haldex special tools where speciﬁed!

8. To remove the two bearings (F) and the spacer (G) on the leading side, assemble in sequence Haldex special tool (K), (L), (D), (A) and (B), as shown in ﬁgure 55.

Once ﬁtted corr

ectly, turn the threaded tool clockwise which will pull out the two bearings (F) and the spacer (G).

If required, rotate the mandrel (A) half way through the extraction process so the nut (B) can be held.

10.

The composite bushing (H) on the trailing side should be r

11.

However if this is not possible, assemble in

emovable by hand.

sequence Haldex special tool (K), (L), (D), (A) and (B), as shown in ﬁgur

e 56.

Figure 55. Remove the leading slide bearing

12.

Once ﬁtted corr

ectly, turn the threaded tool clockwise which will pull out the composite bushing.

Figure 56. Remove the trailing side composite bushing

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ModulTService Guide

4.7.3 Cleaning

IMPORTANT! Use a vacuum cleaner to clean surfaces. Do not use compressed air

IMPORTANT! It is important to take care when using chemicals and/or cleaning tools (e.g. knife, brush, etc). This to avoid damage or displacement of hoses, seals and other components.

Clean the bearing/bush/bellows sealing surfaces of the caliper to ensur moisture, corrosion and damage. See ﬁgure 57.

e they are free from dirt,

If the sealing surfaces have lost their pr

otective surface coating, apply/smear a small amount of general purpose grease over the whole area so when parts are reﬁtted the grease will provide corrosion protection.

ModulT_043

Figure 57. Clean the caliper bearing/bushing mating surfaces

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ModulT Service Guide

4.7.4 Install Slide Function Assembly

IMPORTANT! To secure correct function: Verify that the rotating bearing surface on (L) is facing towards the ﬂange on (K).

IMPORTANT! Only use Haldex special tools where speciﬁed!

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), see ﬁgure 58.

2. To install the two new bearings (F) and the new spacer (G) on the leading side, assemble in sequence (K), (L), (A), (C) and (B), preloaded with the new parts, as shown in ﬁgure 59.

Once ﬁtted corr

ectly, turn the threaded tool clockwise which will pull into position the two bearings (F) and spacer (G) complete.

Stop once the bearings ar

e seated in the correct

position up to the inside lip of the bearing

Figure 58. Install the leading slide bearings and trailing side bushing

Figure 59. Tool assembly for leading slide bearings

F G F

2016

location surface, see ﬁgure 60.

ModulTService Guide

It is important the bearings are seated correctly

but not over tightened as this may cause damage.

5. To install the new composite bushing (H) on the trailing side, by hand, push the composite

ModulT_083

Figure 60. Leading side bearings installed OK/Not OK

IMPORTANT! The trailing side composite bushing must be indexed correctly when being installed into position by hand. If not correctly indexed the slide function of the brake will not be correct.

bushing into place, until it bottoms out. Ensure the index lug locates correctly in the caliper slot, see ﬁgure 61.

No tools or high forces are required for this ﬁtting process, nor should they be used! If used they may cause damage!

If the bushing is not indexed correctly the slide pin and protective cup may not ﬁt!

By hand, ﬁrmly push the two new slide pin

6. bellows into their caliper locations ensuring that

ModulT_093

Figure 61. Inserting the trailing side composite bushing.

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ModulT Service Guide

IMPORTANT! When inserted the slide pin bellows must seat correctly, bottoming out against the caliper location shoulder.

the bellows are seated correctly in position, see ﬁgure 62.

It is important to check that the bellows is correctly seated within the caliper, do so by looking inside the bellows to see their seating.

Failure to do so may compromise the sliding function of the brake.

By hand, insert the leading slide pin (C) into the bearings and the trailing slide pin (D) into the

composite bushing, see ﬁgur

e 63.

ModulT_045

Figure 62. Installing slide pin bellows OK/Not OK.

The longer slide pin (C) is ﬁtted into the leading side.

Note that one end of the slide pins has a machined grove, this side is inserted ﬁrst.

No grease is required.

Check that the bellows location ring is ﬁtted

8. corr

ect 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.

Clean the brake pad contact surfaces on the

9. carrier

, the caliper and the thrust plate. A wire

ModulT_066

Figure 63. Insert the slide pins.

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ModulTService Guide

brush can be used but be careful not to damage any of the bellows. Do not grind! Check to ensure no wear on the carrier pad abutment area. If wear, replace carrier.

10.

Lift the carrier into position in the caliper ensuring that the slide pins ﬁtted with bellows do not

Always use new bolts!

interfer

e or obstruct.

If necessary push out the slide pins slightly by hand whilst lowering in the carrier.

Hold the carrier in position whilst the two bolts are inserted and screwed home. See ﬁgure 64.

11. Using 3/4” long drive 14 mm hexagon tool, screw home and then tighten the slide pin bolts (B). Their torque setting is deﬁned in chapter ”5.2.2 Haldex ModulT ADB”.

12.

efully and squarely tap the protective cups

Car (AT and AL) in place into the caliper using a soft

ModulT_047

Figure 64. Reﬁt the carrier and its ﬁxing bolts

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ModulT Service Guide

IMPORTANT! The protective cups are different sizes and when ﬁtted must be seated correctly. The leading cup is smaller than the trailing cup. The leading cup must bottom out against the bearing and the trailing cup must bottom out against the caliper shoulder

headed mallet.

Note that the cups are different sizes, the larger cup is ﬁtted to the trailing side (AT) and the smaller to the leading side (AL).

The leading protective cup (AL) seats raised from the casting surface whilst the trailing protective cup (AT) sits nearly ﬂush.

OKOK

13.

Do not strike the cups har

d or at an angle as this may damage them and therefore compromise the sliding function of the brake.

Ensur

14.

e the protective cups are correctly seated

and bottomed out, see ﬁgure 65.

ModulT_081

Figure 65. Correctly seating the protection cups OK/Not OK/Not OK/Not OK.

4.7.5 Final Procedure

To conclude this procedure read and follow chapters:

“4.9.3 Install Disc Brake”;

“4.2.3 Install Brake Pads“;

“4.5.3 Install Brake Chamber”;

”3.4 Function Test” to ensure that the disc brake is working correctly;

”3.5 Final Pr

ocedure”.

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ModulTService Guide

4.8 Replacement of Reset Shaft Complete

4.8.1 Initial Procedure

Read and follow chapter ”3.2 Initial Procedure” prior to removing the reset shaft complete.

IMPORTANT! Only use Haldex special tools where speciﬁed!

4.8.2 Remove Reset Shaft Complete

1. If necessary remove dirt, dust and other possible debris from around the reset shaft area. Ensure the area is clean prior to removing the reset shaft protection plug. (With PWS/PWIS the area around the sensor needs to be clean.)

Remove the r

2. PWI/PWIS you need to remove the sensor. Remove the screw and pull the sensor straight out without changing the setting of the sensor, follow chapter ”4.4.2.3 Remove PWS/PWIS”.)

Using r

3. x-ring complete, see ﬁgure 66.

The x-ring is always ﬁtted to the reset shaft and never removed.

eset shaft protection plug (A). (With

emoval tool pull out the reset shaft (B) with

X-Ring

ModulT_094

Figure 66. Removing the reset shaft

2016

4.8.3 Install Reset Shaft Complete

ModulT Service Guide

Clean the r

eset shaft location surfaces in the caliper housing. Ensure the areas are free from dirt, dust, debris, moisture and corrosion.

Insert T

orx 55 tool into the new reset shaft and by hand insert it into the caliper. Make sure the x-ring is correctly in place.

The reset shaft complete with x-ring already ﬁtted is supplied ready lubricated, no additional grease or other lubrication is required.

Push the r

eset shaft into position by hand, no impact or high forces are required as they may damage the reset shaft.

The resent shaft will click into its position in the center of the gear wheel when fully engaged. See ﬁgure 67.

4. (With PWS/PWIS install the Sensor in the same position as you took it out so that the setting will be the same as before taking the sensor out, follow chapter ”4.4.2.5 Install PWS/PWIS.)

Figure 67. Installing the reset shaft OK/Not OK.

“CLICK”

4.8.4 Final Procedure

To conclude this procedure read and follow chapters:

”3.4 Function T

”3.5 Final Pr

est” to ensure that the disc brake is working correctly;

ocedure”.

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ModulTService Guide

4.9 Replacement of Disc Brake

4.9.1 Initial Procedure

Read and follow the chapters below prior to removing the disc brake.

”3.2 Initial Pr

”4.2.2 Remove Brake Pads”, instruction 1 thr

”4.5.2 Remove Brake Chamber”.

4.9.2 Remove Disc Brake

IMPORTANT! Do not remove the disc brakes retaining bolts until the brakes weight is supported by the lifting straps!

Reﬁt the old pad r

1. housing end in the caliper aperture, then locating the pad retainer slot over the caliper latch, ﬁnally slide the pad retainer under the caliper latch until the pad retainer spring pops into locking position. See ﬁgure 68.

ocedure”;

ough to 5 only;

etainer by ﬁrst locating the

Check that the spring bracket is correctly engaged!

Attach a lifting strap ar

2. Tension the lifting strap so taking the full weight of the brake.

Remove the r

3. and lift away from the axle.

etaining bolts holding the disc brake

ound the pad retainer.

DBT22LT

ModulT_060

Figure 68. Disc brake removal

2016

4.9.3 Install Disc Brake

Clean the mating faces of the new disc brakes

1. carrier and axle. Ensur debris, moisture and corrosion.

e the faces are free from dirt,

ModulT Service Guide

Fit the old pad r pad retainer by ﬁrst locating the housing end in the caliper aperture, then locating the pad retainer slot over the caliper latch, ﬁnally slide the pad retainer under the caliper latch until the pad retainer spring pops into locking position.

Attach a lifting strap ar

3. then lift the brake into position.

Follow the vehicle/axle manufactur

4. recommendations for ﬁtting/tightening the retainingbolts, or follow the general method described hereafter.

Fit and scr

5. from side to side of the carrier.

6. Tighten all retaining bolts to the torque settings deﬁned by the vehicle/axle manufacturers speciﬁcations.

etainer spring, then reﬁt the old

Check that the spring bracket is correctly engaged!

ound the pad retainer and

er´s

ew home the retaining bolts, alternating

Remove the lifting strap, old pad r

7. retainer spring. Scrap the old pad retainer and pad retainer spring as they are not to be used again.

etainer and pad

4.9.4 Final Procedure

To conclude this procedure read and follow chapters:

“4.2.3 Install Brake Pads“;

“4.5.3 Install Brake Chamber”;

”3.4 Function T

4. ”3.5 Final Procedure”.

est” to ensure that the disc brake is working correctly;

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ModulTService Guide

ModulT_002

Specications

The Haldex ModulT Air Disc Brake come both left and right handed, it is important the correct hand is ﬁtted in relation to the normal wheel/disc rotation.

Figure 69 below shows a general overview of both variants and their relation to the normal wheel/disc rotation, shown as a red arrow, and their leading (AL) and trailing (AT) slide functions.

Each caliper also has a rotation arrow formed on the cast surface where the pad retainer seats on the inboard side, see ﬁgure 69.

Figure 69. Haldex ModulT orientation

5.1 Wear Limits

Brake Pads, min. lining thickness ................................. 0.08 in (2 mm)

Brake Pad, max. uneven wear ..................................... ± 0.06 in (± 1.5 mm)

Brake disc, min. thickness ............................................... 1.5 in (37 mm) *

* Note. always refere to vehicle/axle manufacturers recommendations.

5.2 Tightening Torques

5.2.1 General

Follow the vehicle/axle manufacturers recommendations.

5.2.2 Haldex ModulT ADB

Bolts x2 for slide pins ................................. 130 ft-lbs + 70° (180 Nm + 70°)

Brake chamber ﬁxation nuts ........................ 130 ft-lbs ± 15 ft-lbs (180 ±20 Nm)

PWS/PWIS scr

ew ............................................... 18 ft-lbs (24 Nm)

2016

Tools

6.1 Haldex ModulT Tool Kit complete

Part Number (P/N) 791-95231

ModulT Service Guide

Figure 70. Haldex ModulT tool kit

6.2 Special tools for Haldex ModulT.

Contents of tool kit Haldex P/N 791-95231.

A Mandrel for the removal and assembly of slide function Bearings and Composite Bushing B Nut for the removal and assembly of slide function Bearings and Composite Bushing C Clamp washer for the assembly of slide function Bearings and Composite Bushing D Cup for the removal of slide function Bearings and Composite Bushing E Mounting tool for thrust plate bellows onto the thrust plate F Mounting tool for thrust plate bellows into the caliper - Left G Mounting tool for thrust plate bellows into the caliper - Right H 3/4” drive long reach 14mm hexagon for slide pin bolts I 3/8” drive Torx T55 for the Reset Shaft J Special tool for removing Reset Shaft Complete

K Threaded spindle used with Pull-out/Pull-in tool pieces

L Axial bearing used with the threaded bar

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ModulTService Guide

Fault Finding

Take all necessary Safety Precautions before wheel removal! Read the Safety Precautions carefully. The vehicle manufacturer’s instructions shall also be followed!

Symptoms Actions

See the relevant chapters for remedial measures

No or low brake force

Are the pads worn out? Replace the pads.

Is the difference between inner/outer pad wear >0.2 in (> 5 mm)?

Is pad/disc clearance OK? Conduct initial setting + function checks.

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 (>5 mm) you need to be aware why to ensure continued correct running and service operations. What you need to consider and check is:

ADB installation

Sliding functions: check that nothing is blocking the calipers full movement (strapped hoses);

On steering axle, check that nothing is forcing the caliper to brake in steering end positions;

Mechanical wear

A Pad used in wet, dirty and/or salty environment will wear faster than pads running in dry clean conditions. Differential pad wear can occur even on the same wheel end where the wheel rim shields the outer pad, so the inner wears faster. Do you use dirt shields on your vehicle? If not, this could be one reason of this pad wear difference

Driving input

If the driver brakes aggressively then as a result it could run higher than average running temperatures and cause differential pad wear;

Driving conditions

Driving with frequent stops and high running temperatures will inevitably cause higher than average pad wear and in some cases differential pad wear;

If it is not possible to ﬁnd the reason for differential pad wear >0.2 in (>5 mm) then perform chapters

3.3.3 Inspections & 3.4 Function Test to ensure correct ADB operation and function.

Is the brake disc OK? Replace the brake disc (See vehicle manufacturer’s

instructions.)

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ModulT Service Guide

No or low brake force

Is air pressure in the brake chamber OK? (Measur

e with a pressure gauge at the brake

chamber) Has the drain plug been removed from the brake

chamber housing? Does the mechanism and caliper move freely? Conduct initial settings and function check.

The brakes pull to one side

Are the pads worn on one side? Replace the pads.

Is pad/disc clearance OK? Conduct initial setting + function checks.

Implement remedial measures according to vehicle manufacturer’s instructions.

Remove the drain plug located at the lowest point of the brake chamber.

Can the pads move freely in the carrier?

Is there the same pressure in both brake chambers of the axle during braking?

Remove the brake pads, clean the pads, carrier and caliper

See the vehicle manufacturer’s instructions for more

information. (Measure with pressure gauge at the brake chambers.)

Has one of the drain plugs been removed from the

Remove the drain plug located at the lowest point. brake chamber housing?

Brakes are binding/not releasing/have heat-damaged components /brake pads wear out quickly.

Does brake pressure remain in the brake chamber when the brakes are released?

Are all of the spring brake chambers released when the parking brake is off?

See the vehicle manufacturer’s instructions for information.

See the vehicle manufacturer’s instructions for

information Is pad/disc clearance OK? Conduct initial setting + function checks. Can the pads move freely in the carrier? Remove the brake pads, clean the pads, carrier and

caliper. Is the caliper slide function OK? Conduct check slide function. Is the wheel bearing clearance OK? See the vehicle manufacturer’s instructions for

information. Has one of the drain plugs been removed from the

Remove the drain plug located at the lowest point. brake chamber housing?

Has valve adjustment/brake force distribution been carried out correctly?

Adjust brake valves/carry out brake force

adaptation. Refer also to vehicle manufacturer’s

instructions. Uneven pad wear or pads wearing out too quickly? Work through the inspections chapter to ensure the

brake is functioning correctly and thus identify any

operational problems requiring rectiﬁcation.

Also check that genuine Haldex brake pads are

being used, only use Haldex original spare parts!

Check that the correct brake pad friction material is

being used for the speciﬁc application.

Check the brake harmonisation between the truck

and trailer is correctly setup.

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ModulTService Guide

Noise/ vibrations from the brake

Can the pads move freely in the carrier? Remove the brake pads, clean the pads, carrier and

caliper, then reﬁt.

Are there non-permitted cracks/grooves on the brake disc?

Is the brake disc’s run-out within speciﬁed parameters?

Is the disc brake and its components ﬁxed to the axle as speciﬁed?

Probably need to change the brake disc. See the vehicle manufacturer’s instructions for more information.

If not then probably need to change the brake disc. See the vehicle manufacturer’s instructions for more information.

See the vehicle manufacturer’s instructions for more information.

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ModulT Service Guide

Component List and Exploded view

8.1 Component List

Haldex ModulT Air Disc Brake

010 Air Disc Brake Assemblies Complete - Left Hand & Right Hand 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

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ModulT_052

030

150

LH RH

160

010

170

180

040

030

050

210

020

190

060

070

120

130

080

140

090

060

100

160

8.2 Exploded view

ModulTService Guide

2016

ModulT Service Guide

2016

inside back cover - blank

With more than 100 years of intensely focused innovation, Haldex holds

unrivaled expertise in brake systems and air suspension systems for heavy

trucks, trailers and buses. We live and breathe our business, delivering robust,

technically superior solutions born from deep insight into our customers’ reality.

By concentrating on our core competencies and following our strengths and

passions, we combine both the operating speed and exibility required by the

market. Collaborative innovation is not only the essence of our products - it is also our philosophy. Our employees, spread on four continents, are constantly

challenging the conventional and strive to ensure that the products we deliver

create unique value for our customers and all end-users.

To learn more, contact your Haldex sales professional.

United States 816-891-2470 Canada 519-621-6722 Mexico 52-81-81569500

For additional contact information or to learn more about Haldex, please visit Haldex.com

L30048

US 9/19 500 LS

Printed In The USA

Haldex Modult User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual