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GEN.0000000005086 Rev E
© 2017 SRAM, LLC
Level™ Ultimate, TLM & TL
Service Manual
2
SRAM LLC WARRANTY
EXTENT OF LIMITED WARRANTY
Except as otherwise set forth herein, SRAM warrants its products to be free from defects in materials or workmanship for a period of two years after
original purchase. This warranty only applies to the original owner and is not transferable. Claims under this warranty must be made through the
retailer where the bicycle or the SRAM component was purchased. Original proof of purchase is required. Except as described herein, SRAM makes
no other warranties, guaranties, or representations of any type (express or implied), and all warranties (including any implied warranties of
reasonable care, merchantibility, or fitness for a particular purpose) are hereby disclaimed.
LOCAL LAW
This warranty statement gives the customer specific legal rights. The customer may also have other rights which vary from state to state (USA), from
province to province (Canada), and from country to country elsewhere in the world.
To the extent that this warranty statement is inconsistent with the local law, this warranty shall be deemed modified to be consistent with such law,
under such local law, certain disclaimers and limitations of this warranty statement may apply to the customer. For example, some states in the United
States of America, as well as some governments outside of the United States (including provinces in Canada) may:
a. Preclude the disclaimers and limitations of this warranty statement from limiting the statutory rights of the consumer
(e.g. United Kingdom).
b. Otherwise restrict the ability of a manufacturer to enforce such disclaimers or limitations.
For Australian customers:
This SRAM limited warranty is provided in Australia by SRAM LLC, 1000 W. Fulton Market, 4th Floor, Chicago, IL, 60607, USA. To make a warranty
claim please contact the retailer from whom you purchased this SRAM product. Alternatively, you may make a claim by contacting SRAM Australia, 6
Marco Court, Rowville 3178, Australia. For valid claims SRAM will, at its option, either repair or replace your SRAM product. Any expenses incurred in
making the warranty claim are your responsibility. The benefits given by this warranty are additional to other rights and remedies that you may have
under laws relating to our products. Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled
to a replacement or refund for a major failure and for compensation for any other reasonably foreseeable loss or damage. You are also entitled to
have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure.
LIMITATIONS OF LIABILITY
To the extent allowed by local law, except for the obligations specifically set forth in this warranty statement, in no event shall SRAM or its third party
suppliers be liable for direct, indirect, special, incidental, or consequential damages.
LIMITATIONS OF WARRANTY
This warranty does not apply to products that have been incorrectly installed and/or adjusted according to the respective SRAM user manual. The
SRAM user manuals can be found online at sram.com, rockshox.com, avidbike.com, truvativ.com, or zipp.com.
This warranty does not apply to damage to the product caused by a crash, impact, abuse of the product, non-compliance with manufacturers
specifications of usage or any other circumstances in which the product has been subjected to forces or loads beyond its design.
This warranty does not apply when the product has been modified, including, but not limited to any attempt to open or repair any electronic and
electronic related components, including the motor, controller, battery packs, wiring harnesses, switches, and chargers.
This warranty does not apply when the serial number or production code has been deliberately altered, defaced or removed.
This warranty does not apply to normal wear and tear. Wear and tear parts are subject to damage as a result of normal use, failure to service according
to SRAM recommendations and/or riding or installation in conditions or applications other than recommended.
Wear and tear parts are identified as:
Notwithstanding anything else set forth herein, the battery pack and charger warranty does not include damage from power surges, use of improper
charger, improper maintenance, or such other misuse.
This warranty shall not cover damages caused by the use of parts of dierent manufacturers.
This warranty shall not cover damages caused by the use of parts that are not compatible, suitable and/or authorised by SRAM for use with SRAM
components.
This warranty shall not cover damages resulting from commercial (rental) use.
• Dust seals
• Bushings
• Air sealing o-rings
• Glide rings
• Rubber moving parts
• Foam rings
• Rear shock mounting hardware
and main seals
• Upper tubes (stanchions)
• Stripped threads/bolts (aluminium,
titanium, magnesium or steel)
• Brake sleeves
• Brake pads
• Chains
• Sprockets
• Cassettes
• Shifter and brake cables (inner
and outer)
• Handlebar grips
• Shifter grips
• Jockey wheels
• Disc brake rotors
• Wheel braking surfaces
• Bottomout pads
• Bearings
• Bearing races
• Pawls
• Transmission gears
• Spokes
• Free hubs
• Aero bar pads
• Corrosion
• Tools
• Motors
• Batteries
3Table of Contents
TABLE OF CONTENTS
BRAKE SERVICE OVERVIEW ............................................................................................................................................................5
TROUBLESHOOTING .......................................................................................................................................................................................................................................6
SRAM LEVEL™ ULTIMATE & TLM CALIPER SERVICE ....................................................................................................................... 7
PARTS AND TOOLS NEEDED FOR SERVICE............................................................................................................................................................................................7
LEVEL CALIPER EXPLODED VIEW ..............................................................................................................................................................................................................7
CALIPER BRAKE PAD REMOVAL ..................................................................................................................................................................................................................8
CALIPER PISTON REMOVAL ..........................................................................................................................................................................................................................9
CALIPER PISTON INSTALLATION .............................................................................................................................................................................................................. 13
SRAM LEVEL™ TL CALIPER SERVICE .............................................................................................................................................. 16
PARTS AND TOOLS NEEDED FOR SERVICE..........................................................................................................................................................................................16
SRAM LEVEL TL CALIPER EXPLODED VIEW..........................................................................................................................................................................................16
CALIPER BRAKE PAD REMOVAL ................................................................................................................................................................................................................ 17
CALIPER PISTON REMOVAL ........................................................................................................................................................................................................................18
CALIPER PISTON INSTALLATION ..............................................................................................................................................................................................................21
LEVER SERVICE ............................................................................................................................................................................. 24
PARTS AND TOOLS NEEDED FOR SERVICE......................................................................................................................................................................................... 24
LEVEL™ ULTIMATE LEVER EXPLODED VIEW ......................................................................................................................................................................................... 24
LEVEL™ TLM & TL LEVER EXPLODED VIEW ........................................................................................................................................................................................... 25
LEVER BLADE REMOVAL.............................................................................................................................................................................................................................26
PISTON ASSEMBLY REMOVAL ................................................................................................................................................................................................................... 31
PISTON ASSEMBLY INSTALLATION .........................................................................................................................................................................................................32
LEVER BLADE INSTALLATION ................................................................................................................................................................................................................... 33
4Table of Contents
SAFETY FIRST!
We care about YOU. Please, always wear your safety glasses and protec-
tive gloves when servicing SRAM® products.
Protect yourself! Wear your safety gear!
5Brake Service Overview
Brake Service Overview
SRAM brake systems need to be serviced periodically to optimize braking function. If brake fluid is leaking from any area of the brake there may be
damage or wear and tear to the internal moving parts. If the system has been contaminated with the wrong fluid there may be damage to all rubber
and plastic internal parts. If your brake was damaged in a crash there may be damage to the lever blade, pushrod, and brake assemblies. Inspect and
replace these parts to restore proper brake function.
Your product's appearance may differ from the pictures contained in this publication.
SAFETY INSTRUCTIONS
• Servicing your brakes removes all of the brake fluid from the system. You must bleed your brakes after you service the brake caliper and/or lever.
• Always wear safety glasses and nitrile gloves when working with DOT fluid.
• Place an oil pan on the floor where you will be working on the brake.
• Used DOT fluid should be recycled or disposed of in accordance to local and federal regulations.
• Never pour DOT fluid down a sewage or drainage system or into the ground or a body of water.
• DOT fluids will damage painted surfaces. If any fluid comes in contact with a painted surface (i.e. your frame) or printing on the brakes, wipe it off
immediately and clean it with isopropyl alcohol or water. Damage to painted and/or printed surfaces by DOT fluid is not covered under warranty.
• Do not allow any brake fluid to come in contact with the brake pads. If this occurs, the pads are contaminated and must be replaced.
• For best results, use only SRAM DOT 5.1 fluid. If SRAM fluid is not available, only use DOT 5.1 or 4 fluid.
Do not use mineral oil or DOT 5 fluid.
6Troubleshooting
Troubleshooting
If your levers have excessive brake lever throw, it may be a result of the pistons sticking in the caliper. Before bleeding the system, you can try to
loosen the sticky piston by performing the following steps:
1. Clamp the bicycle into a bicycle work stand.
2. Remove the wheel from the affected caliper.
3. Squeeze the brake lever several times until the brake pads nearly contact one another.
4. Insert the Level™ pad spreader between the brake pads to spread the pads to the full width of the clip.
5. Remove the Level pad spreader.
6. Repeat steps 3-5.
7. Reinstall the wheel.
8. Squeeze the brake lever several times to position the brake pads to the proper distance from the rotor.
9. Center the caliper on the rotor if necessary.
10. Spin the wheel and check the brake function. The pistons should move freely and there should not be excessive brake lever throw.
If there is no improvement in the brake function, proceed with caliper service.
7SRAM Level™ Ultimate & TLM Caliper Service
SRAM Level™ Ultimate & TLM Caliper Service
We recommend that you have your SRAM Level brakes serviced by a qualified bicycle mechanic. Servicing SRAM brakes requires knowledge of brake
components as well as the special tools and fluids used for service.
For exploded diagram and part number information, please refer to the Spare Parts Catalog available on our website at
sram.com/service. For order information, please contact your local SRAM distributor or dealer.
Information contained in this publication is subject to change at any time without prior notice. For the latest technical information, please visit our
website at sram.com/service.
Your product's appearance may dier from the pictures contained in this publication
P arts and Tools Needed for Service
• Safety glasses
• Nitrile gloves
• Oil pan
• Isopropyl alcohol
• Level bleed block
• SRAM monoblock caliper 21 mm piston removal tool
• Digital caliper
• SRAM DOT 5.1 Fluid
If SRAM fluid is not available, only use DOT 5.1 or 4 fluid
• 8mm Flare nut crowfoot wrench
• Pick
• T8 & T25 TORX® wrenchs
• T25 TORX bit socket
• Torque wrench
• 2.5 mm hex wrench
• Clean, lint-free shop towel
• Level pad spreader
• Air compressor with a rubber-tipped chuck nozzle
• Soft rubber or piece of inner tube
• Level pad spreader
Level C aliper Exploded View
E-clip
Banjo
o-ring
Banjo
bolt
Pad retention bolt
Caliper piston
Caliper piston
Piston seal
Piston seal
Brake pads
H-spring
Bleed port
Banjo
Bleed
port
plug
Caliper
Hose
8Caliper Brake Pad Removal
Caliper Brake Pad Removal
NOTICE
DOT fluid will damage painted surfaces. If any fluid comes in contact with a painted surface (i.e. your frame) or printing on the brakes, wipe it off
immediately and clean it with isopropyl alcohol or water. Damage to painted and/or printed surfaces by DOT fluid is not covered under warranty.
Use a T25 TORX
®
wrench or a 5 mm hex wrench to remove the brake
caliper from the fork or frame.
Remove the caliper, mounting bracket, and hardware from the caliper,
then set them aside in the order that they were removed.
Use needle nose pliers to remove the E-clip from the pad retention bolt.
Use a 2.5 mm hex wrench to remove the pad retention bolt from the
caliper.
Remove the brake pads from the caliper.
NOTICE
Brake pads must be replaced if the total thickness of the backing plate
and pad friction material is less than 3 mm.
1
2
Needle nose pliers 20 mm or 15 mm Thru Axle
2.5 mm hex wrench QR
3
Digital caliper 2.7-3.2 N•m (24-28 in-lb) 22 mm
9Caliper Piston Removal
Caliper Piston Removal
NOTICE
DOT fluid will damage painted surfaces. If any fluid comes in contact with a painted surface (i.e. your frame) or printing on the brakes, wipe it off
immediately and clean it with isopropyl alcohol or water. Damage to painted and/or printed surfaces by DOT fluid is not covered under warranty.
Use a T25 TORX
®
wrench to remove the banjo bolt and hose.
Insert the SRAM monoblock caliper 21 mm piston removal tool, then use
a 2.5 mm hex wrench to install the pad retention bolt into the caliper.
⚠ CAUTION
The pad retention bolt must be installed. If the pad retention bolt is not
installed the SRAM piston removal tool may dislodge rapidly from the
caliper, which can lead to bodily injury or damage to the parts.
1
T25 TORX wrench Rubber-tipped blow gun chuck nozzle 22 mm
2
SRAM piston removal tool 20 mm or 15 mm Thru Axle
10Caliper Piston Removal
Firmly press a rubber-tipped air chuck nozzle into the banjo port. Hold
the caliper securely against a rubber surface and force air into the
banjo port to dislodge the piston from the caliper.
⚠ CAUTION - EYE HAZARD
Wear safety glasses.
The caliper piston may dislodge rapidly from the caliper, which can lead
to bodily injury or damage to the parts. Point the caliper piston toward a
rubber surface to prevent the piston from becoming a projectile.
Remove the pad retainer bolt, then remove the SRAM piston removal
tool from the caliper.
Insert the Level piston plug so that it fits snugly into the empty piston
bore and is flush with the inside of the caliper.
3
T25 TORX wrench Rubber-tipped blow gun chuck nozzle 22 mm
4
Level piston plug 20 mm or 15 mm Thru Axle
5
11Caliper Piston Removal
Insert the SRAM piston removal tool so that it will capture the
still-installed piston. Make sure the horse-shoe opening is aligned with
the tab on the piston plug.
Use a 2.5 mm hex wrench to install the pad retention bolt in order to
hold the piston removal tool in place.
⚠ CAUTION
The pad retention bolt must be installed. If the pad retention bolt is not
installed the SRAM piston removal tool may dislodge rapidly from the
caliper, which can lead to bodily injury or damage to the parts.
Insert a rubber-tipped blow gun chuck nozzle into the banjo port, then
place a towel over the caliper to contain any dislodged fluid.
⚠ CAUTION
Wear safety glasses.
The caliper piston may dislodge rapidly from the caliper, which can lead
to bodily injury or damage to the parts. Point the caliper pistons toward
a rubber surface before forcing air into the caliper.
While firmly pushing against the caliper half and chuck nozzle, squeeze
the air chuck to force air into the banjo port and dislodge the piston
from the caliper.
Continue to force air into the caliper until the piston is dislodged. Turn
the caliper over and the piston will fall out easily.
Remove the SRAM piston removal tool and piston plug from
the caliper.
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SRAM piston removal tool 20 mm or 15 mm Thru Axle
2.5 mm hex wrench Rubber-tipped blow gun chuck nozzle 22 mm
Rubber-tipped blow gun chuck nozzle Rubber-tipped blow gun chuck nozzle 22 mm
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12Caliper Piston Removal
Use a pick to remove the piston seals from each piston bore.
⚠ CAUTION
Do not scratch the seal gland with the pick. Scratches could cause fluid
to leak when the brake is applied, which will contaminate the brake
pads and could lead to a brake failure.
Spray isopropyl alcohol inside each piston bore, the inside and the
outside of the caliper, and all of the removed parts and clean them with
a shop towel.
NOTICE
If the system has been contaminated with mineral oil or DOT 5 fluid,
flush all of the parts with soapy water, rinse them with clean water, then
allow all of the parts to dry prior to rebuilding. Install all new seals and a
new brake hose.
For the best braking performance, use only SRAM DOT 5.1 fluid. If SRAM
fluid is not available, use only DOT 5.1 fluid or 4 fluid.
Pick Rubber-tipped blow gun chuck nozzle 22 mm
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