FREEDOM™ MEDIUM DUTY TRUCKS DISC BRAKE SERVICE FOR WABCO PAN 19 SERVICE MANUAL& DISC BRAKE SERVICE FOR WABCO PAN 19 SERVICE MANUAL FREEDOM™ MEDIUM DUTY TRUCKSATTENTION The information in this manual is not all inclusive and cannot take into account all unique situations. Note that some illustrations are typical and may not reflect the exact arrangement of every component installed on a specific chassis. The information, specifications, and illustrations in this publication are based on information that was current at the time of publication. No part of this publication may be reproduced, stored in a retrieval system, or be transmitted in any form by any means including (but not limited to) electronic, mechanical, photocopying, recording, or otherwise without prior written permission of Mack Trucks, Inc.TABLE OF CONTENTS TABLE OF CONTENTS ia» TABLE OF CONTENTS INTRODUCTION . : SAFETY INFORMATION ... ‘Advisory Labels Service Procedures and Tool Usage . Safety Tips to be Considered During Repait CONVERSION CHART way DESCRIPTION AND OPERATION ..... DISC BRAKE ASSEMBLIES . Operation ........ COMPONENT LOCATOR ....... COMPONENT LOCATIONS REPAIR INSTRUCTIONS . BRAKE CHECKS . Checking the AirGap ...... Checking the Automatic Adjuster . Cheeking the Brake Pads .. BRAKE PAD REPLACEMENT Removing the Brake Pads . Inspecting the Dust Caps and Checking Brake Caliper Movement . Installing the Brake Pads ..... BRAKE CALIPER ASSEMBLY REPLACEMENT Removing the Brake Caliper... . Installing the Brake SEAL REPLACEMENT _ Removing the Dust Caps and Guide Pins Replacing the Guide Bushings Installing the Guide Pin Dust Caps... Replacing the Dust Gaps and Adjustr Sorew Thnist Cups. BRAKE DISC REPLACEMENT . : i Inspecting the Brake Disc . Replacing the Brake Disc... : BRAKE CHAMBER REPLACEMENT ... Removing the Brake Chamber . Installing the Brake Chamber . . : Removing the Spring-Loaded Chamber... Installing the Spring-Loaded Chamber .... SPECIFICATIONS ........ BRAKE SPECIFICATIONS. . Torque Specifications — Lb-Ft (Nem) Brake Disc and Pad Material Specifications ...... Symbols ...... SPECIAL TOOLS & EQUIPMENT .......... SPECIAL TOOLS Specifications ..... Le ooes INTRODUCTION INTRODUCTIONINTRODUCTION SAFETY INFORMATION Advisory Labels Cautionary signa! words (Danger-Warning-Caution) may appear in various locations throughout this manual. Information accented by one of these signal words must be observed to minimize the risk of personal injury to service personnel, or the possibility of improper service methods which may damage the vehicle or cause it to be unsafe. Additional Notes and Service Hints are used to emphasize areas of procedural importance and provide suggestions for ease of repair. The following definitions indicate the use of these advisory labels as they appear throughout the manual: PT a Activities associated with Danger indicate that death or serious personal injury may result from failing to heed the advisory. Serious personal injury may be equated to career-ending injury. te that personal injury may result from failing to heed the advisory. In this case, personal injury is not equated to career-ending injury, but results in possible change in quality of life. ACAUTION Activities associated with Caution indicate that product damage may result from failing to heed the advisory. Caution is not used for personal injury. NOTE ‘A procedure, practice, or condition that is essential to emphasize SERVICE HINT A helpful suggestion that will make it quicker and/or easier to perform a procedure, while possibly reducing service cost. Page 2INTRODUCTION Service Procedures and Tool Usage Anyone using a service procedure or tool not recommended in this manual must first satisfy himself thoroughly that neither his safety nor vehicle safety will be jeopardized by the service method he selects. Individuais deviating in any manner from the instructions provided assume all risks of consequential personal injury or damage to equipment involved. ‘Also note that particular service procedures may require the use of a special tools) designed for a specific purpose. These special tools must be used in the manner described, whenever specified in the instructions. 1. Before starting a vehicle, always be seated in the driver's seat, place the transmission in neutral, be sure that parking brakes are set, and disengage the clutch. 2. Before working on a vehicle, place the transmission in neutral, set the parking brakes, and block the wheels. 3. Before towing the vehicle, place the transmission in neutral and lift the rear wheels off the ground, or disconnect the driveline to avoid damage to the transmission during towing. Engine-driven components such as Power Take-Off (PTO) units, fans and fan belts, driveshafts and other related rotating assemblies, can be very dangerous. Do not work on or service engine-driven components unless the engine is shut down. Always keep body parts and loose clothing out of range of these powerful components to prevent serious personal injury. Be aware of PTO engagement or nonengagement status. Always disengage the PTO when not in use. REMEMBER, SAFETY ... IS NO ACCIDENT! Page 3INTRODUCTION Mack Trucks, Inc. cannot anticipate every possible occurrence that may involve a potential hazard. Accidents can be avoided by recognizing potentially hazardous situations and taking necessary precautions. Performing service procedures correctly is critical to technician safety and safe, reliable vehicle operation. The following list of general shop safety practices can help technicians avoid potentially hazardous. situations and reduce the risk of personal injury. DO NOT perform any services, maintenance procedures or lubrications until this manual has been read and understood. * Perform all service work on a flat, level surface. Block wheels to prevent vehicle from rolling. + DO NOT wear loose-fiting or tom clothing, Remove any jewelry before servicing vehicle. * ALWAYS wear safety glasses and protective shoes. Avoid injury by being aware of sharp comers and jagged edges. Use hoists or jacks to lift or move heavy objects. NEVER run engine indoors unless exhaust fumes are adequately vented to the outside, Be aware of hot surfaces. Allow engine to cool sufficiently before performing any service or tests in the vicinity of the engine. Keep work area clean and orderly. Clean up any spilled oil, grease, fuel, hydraulic fluid, etc. Only use tools that are in good condition, and always use accurately calibrated torque ‘wrenches to tighten all fasteners to specified torques. In instances where procedures require the use of special tools which are designed for a specific purpose, use only in the manner described in the instructions. Do not store natural gas powered vehicles indoors for an extended period of time (overnight) without first removing the fuel. Never smoke around a natural gas powered vehicle. Page 4INTRODUCTION Safety Tips to be Considered During Repair The flawless technical condition of the disc brake is of utmost importance to ensure good driving and safe braking characteristics. Observe the wear limits of the brake pads and brake disc. When brake pads or brake disc are damaged, or worn beyond their specified minimum thickness, brake effectiveness will diminish and possibly result in an accident. During repairs on the brake, the vehicle must be parked on a tevel surface and be blocked to prevent rollaway. Only approved and suitable fixtures are to be used for the lifting and blocking of the vehicle, While working on the brake, it must be ensured that the brake cannot be actuated inadvertently, Do not actuate the brake when brake pads are temoved Do not clean the brake with pressurized ait or other high-pressure cleaning apparatus. A second technician should assist during removal and installation of the brake. During repairs outside of the vehicle, the brake must be secured in a fixture, such as a heavy vise, as high torque is required during removal and installation of the bolts. NOTE ‘The brake caliper with clamping unit should not be opened. Therefore, the bolts holding the cover should not be loosened. No serviceable parts are inside the clamping ur Only original and genuine Service Parts are to be used. For lubrication, use only the tube ot grease supplied with the brake repair kit. Install only brake pads approved by the vehicle manufacturer. With newly installed brake pads, avoid emergency stops and long braking cycles to prevent excessive temperatures. During repairs, use only recommended tools, Tighten nuts and bolts only to specified torque limits, ‘When wear of the cast brake parts, such as cracks or heavy abrasion, is observed, replace the entire brake assembly according t0 instructions. Upon completion of repairs, the vehicle's braking system must be tested on a roller dynamometer. Ino roller dynamometer is available, a driving test with brake applications must be performed, Page 5INTRODUCTION CONVERSION CHART Conversion Units Multiply By: Tength Galculations tnches (in) 0 Milimeters (rm) 25.40 a Inches (in) 0 Centimeters (em) 2540 Feet (i) 0 Centimeters (em) 3048 Feot () 0 Meters (mm) 0.048 Yards (va) 0 Centimeters (em) ota Yards (ya) to Mators (m) o.9t44 Miles to Kilometers (rn) 5608 Milimeters (rm) to Taches (in) 0.08887 Centimeters (em) to Taches (in) (0.3057 Centimeters (em) to Feat t) 0.0828 Centimeters (em) 6 Yards (yd) 0.0108 Meters (rm) to Feet () 3281 Meters (rm) 6 Yards (ya) 7.098 Kilometers (kin) to | Miles oeeia ‘Area Calculations Square inches (ea) o ‘Square Milimetors (eqn) 64: ‘Square Inches (69-n) to ‘Square Centimeters (sqm) 6.482 ‘Square Feet (6a) te ‘Square Centimeters (sqm) 729.0 Square Foot (oe) ‘Square Motors (eqn) 0.0029 7 [ Square Yards (sq-y¢) ‘Square Meters (sq-m) 0.8361 [ Square Miles (se-iles) to ‘Square Kilometers (sak) 2500 ‘Square Milimeters (sq-mm) to | Square Inches (sq-in) 0.00185 | Square Centimeters (sq-om) Tre “Square Inches (sq-in) 0.155 Square Centimeters (sq-om) to Square Foot (oa) o.001076 Square Meters (sqm) to “Square Feet (sar) 10.76 Square Meters (sq) te Square Vards (84-y3) 1.198 Square Kilometers (64-4) to Square Milos (69-168) 0.3861 Volume Calculations Cui Inches (eurn) te ‘Cubic Centimeters (exer) 16387 Cubic Inches (eurin) to Liters (U) 0.01630 Quarts (qt) to Liters (O) 00464 Gallons (gal) ie Liters U) 3.7884 (Cubic Yards (eu-yd) to ‘Cubic Meters (cum) 0.7646 Cubic Centimeters (cu-cm) to ‘Cubic Inches (cu-in) 0.06102, Liters (0) to ‘Cubic Inches (ou-iny 61.028 Liters (L) to ~_ | Quarts (at) 1.0567 ters (L) 0 Gallons (gal) 02642 ‘Gabi Meters (cum - io Cubie Yards (enya) 7308 Page 6INTRODUCTION Conversion Units Multiply By: Weight Calculations Ounces (62) 0 Grams @) 2BBTi4 -| Pound (8) 0 Kilograms (kg) 0.4596 Pounds (1b) to ‘Short Tons (US tons) 0.0005 F Pounds (ib) to Metric Tons (t) 0.00045 Short Tons (US tons) te Pounds (ib) 72000 ‘Shot Tons (US tons) 0 Kllograms (ka) (907.18486 ‘Shor Tons (US tons) © Metric Tons () 0.90718 | Grams) to ‘Ounces (e2) (0.035 | icorars tka} Pounds (ib) 2205 ‘Kilograms (ka) to ‘Shon Tons (US tons) o.0ori02 ‘Kilogram (kg) to Matic Tons () 0.001 | Metric Tons (t) to Pounds (Ib) 2205 ‘Metric Tons () 0 ‘Short Tons (UStons) 1.1088 Matric Tons (t) 0 Kilograms (ka) 1000 Force Calculations ‘Ouncos Force (eel) 6 Newions (N) 07780 Pounds Farce (bi) 0 Newtons (N) 4448 Pounds Force (bf) 6 Kilograms Force (el) 0.486 Kilograms Force (kai) 0 Pounds Force (bf) 2.2046 Kilograms Force (kal) o Newions (N) 9.807 Newtons (N) te Kilograms Force (cl) 0.10186 Newtons (N) to ‘Ounces Foree (oa) 3.597 Wewions (8) to Pounds Force (bi) 0.2088 al Torque Galculations Pound Inches (Ib-in) [to ‘Newton Meters (Nem) 0.11298 am Pound Foot (ft) 6 Newton Meters (Nem) 1.3868 “Pound Feet (ib-ft) 10 Kilograms Force per Meter (kgim) 0.19825, Newton Motors (Nem) 0 Pound inches (bin) 8.61 Newton Meters (Nem) 10 Pound Feet (b-A) o7876 TNowion Meters (Nem) to Kllograms Force per Meter (kgf) 0.10187 Kilograms Force per Meter (kgirn) ‘e Pound Fee (ity 7.233 Kilogram Foree per Meter (kgim) 0 Newton Meters (Nem) 9807 Radiator Specific Heat Dissipation Calculations British Thermal Unit per Hour(8TUMy) | to Kilowatt pet Degree Gelsius (KW/°O) 0.000288 Kilowatt par Degree Calsus (kW) By British Thermal Unitper Hour (BTU) | 9414.48 Temperature Calculations = Degrees Fahrenheit CF) to Degrees Celsius (°C) (Fa2)055 ‘| Degrees Geiss (°O) 0 Degrees Fahrenhek CF} (Bx) +82 Page7INTRODUCTION Conversion Units Muniply By] Pressure Calculations ‘Atmospheres (atm) [| Bars (bar) 1.01325 | ‘Atmospheres (atrn) 0 Kilpascals (Pa) 101.325 Bars (bar) to ‘Atmospheres (atm) 0.98692 Bars (bar) ‘° Kiopascals («Pa 100 Bar (bat) to | Pounds per Square inch (psi) 145087 Inches of Mercury (in Ha) to Kilopascals (kPa) 377 Inches of Water (in H.0) to | Kilopascals (kPa) 24a Pounds per Square Inch (ps) 0 Kilopascals (kPa) 6.898 Pounds por Square Inch (psi) Bar Gar) 0.06895 Kilopascals (KPa) to ‘Amosphores (atm) 0.00987 Kilopascals (KPa) to Inches of Mercury (in Hg) 0.29612 Kilopascals (KPa) ‘ Inches of Water (in HO) a01aas Kilopascals (kPa) to Pounds por Square Inch (psi) 01145, Power Calculations Horsepower hp) Kilowatis (RW) 0.74627 Kiowatts (kW) to Horsepower (hp) 134 Fuel Performance Calculations Miles per Gallon (mile/gal) to Kilometers per Liter (kml) 0.4251 Kilometers pe Liter (km) to Miles per Gallon (milegal) 2.362 | Velocity Calculations Miles per Hour (riot) 1 Kitomotors per Hour (kh 1809 Kilometers per Hour (ahr) to Miles per Hour (lem) oat Volume Flow Calculations Gubic Feet per Minute (cu-vinin) ie Liters per Minute (in) 28.32 Uiters por Minute (Un) te Cubic Feet per Minute (cutvimin) 0.03531 Page 8ai» DESCRIPTION AND OPERATION DESCRIPTION AND OPERATION Page 9DESCRIPTION AND OPERATION DISC BRAKE ASSEMBLIES Operation ‘The “PAN” brake is a floating caliper disc brake, designed for installation on front and rear axles in trucks as a service, emergency and parking brake. The brake is actuated mechanically via a diaphragm or spring-loaded cylinder which is mounted directly to a cover on the brake caliper, resulting in a relatively short overall axial length and compact brake package. The complete brake consists of the brake caliper and the torque plate or brake carrier. ‘The brake caliper floats axially on guide pins on the torque plate, and the brake pads are secured within the torque plate by a hold-down strap. Page 10 The radially open design of the brake caliper allows for simple and quick changes of the brake pads The actuation unit of the brake is equipped with ‘an automatic adjuster to compensate for wear of the brake pads and brake disc. This automatic adjuster, independent of load and operating conditions, maintains a constant predetermined. gap between brake pads and brake disc. This, together with the robust and stiff construction of the brake caliper, ensures safe control of the brake system and increases safety margins during emergency stopping. ‘The internal moving components of the brake are lubricated for life, and all sealing components are maintenance free unless damaged.DESCRIPTION AND OPERATION Figure 1 — Disc Brake Exploded View 1. Hola}Down Strap Hex-Head Bot 11, Dust Cap 2, Hold-Down Strap 12. Cover 8, Brake Pad (wheel sido) 18. Guide Pin Cover (short) 4, Hold-Down Spring 14, Guide Pin Bolt (short) 5, Brake Pad (actuator side) 18. Guide Pin (short) 6. Guide Pin Dust Cap 16. Torque Plate 7. Bushing 17, Brake Caliper 8. Guide Pin (long) 418. Spring Clip 9. Guide Pin Bol (long) 19 Cable Guide 10. Guile Pin Cover (long) Page 14NOTES Page 12COMPONENT LOCATOR COMPONENT LOCATOR Page 13ds COMPONENT LOCATOR COMPONENT LOCATIONS Refer to Figure 2 and Figure 3 for specific "PAN" disc brake component locations. j Figure 2 — “PAN” Dise Brake Exploded View 1. Hold-Down Strap Hex-Head Bolt 2. Hold-Down Strap 3. Brake Pad (wheel side) 4, Hold-Down Spring 5. Brake Pad (actuator side) 6. Guide Pin Dust Cap 7. Bushing 8. Guide Pin (long) 9, Guide Pin Bolt (long) 10, Guide Pin Cover (long) 11, Dust Cap 12, Cover 18, Guide Pin Cover (short) 44, Guide Pin Bott (short) 15, Guide Pin (shor) 16, Torque Plate 17. Brake Caliper 18. Spring Clip 19, Gable Guide Page 14COMPONENT LOCATOR @ O} Ke Fs sooro3 Figure 3 — “PAN” Disc Brake Cross Seation Views: 1. Hold-Down Strap Hex-Head Bolt 2. Holé-Down Strap 3, Brake Pad (weet sido) 4, Hold-Down Spring 5. Brake Pad (actuator side) 6. Guide Pin Dust Cap 7. Bushing 8, Guide Pin (long) ‘8, Guide Pin Bolt (long) 10. Cover (long) 17. Dust Cap. 12, Rubber Plug 18. Cover (short) 14, Guide Pin (shor) 15. Guido Pin Bolt (shor) 16. Torque Plate 17. Brake Caliper 19. Cable Guide 20. Hex Nut on Agiuster Screw Page 15ricci NOTES Page 16& REPAIR INSTRUCTIONS REPAIR INSTRUCTIONS Page 17es) BRAKE CHECKS Checking the Air Gap 1. Loosen and remove the hex-head bolt (3) from the hold-down strap (4). Refer to Figure 4, 2. Pull the hold-down strap (4) out of the brake caliper (1). 3._ Lift off the two hold-cown springs (5). 4, Move the cable guide (2) to the side. NOTE Leave the brake pads in place when checking the air gap. REPAIR INSTRUCTIONS 5. Push the brake caliper (1) toward the wheel and check the gap with the feeler gauge. Allowable gap is 0.03 in. (0.7 mn) to 0.04 in. (1.0 mm). See Figure 5. NOTE Always insert the feeler gauge between the brake caliper (1) and brake pad backing plate (2). It the measured air gap is above the specified limits, the adjuster must be checked, Figure 4 — Removing the Hold-Down Strap Figure § — Checking the Air Gap Page 18REPAIR INSTRUCTIONS Checking the Automatic Adjuster 3. Actuate the brake lightly five times {approximately 14.5 psi/1 bar). When the adjuster functions properly, the closed-end NOTE wrench will retract in. an opposite direction (see arrow). Depending on accessibility, the brake can be synchronously retracted with either the left- or right-hand adjuster spindles, 1. Remove one plug (1) for the adjuster. Refer to Figure 6. 2. Using a closed-end wrench on the adjuster hex nut, set the air gap to 0.08-0.12 in, (2-3 mm). ACAUTION Adjuster testing is only possible with an air gap between 0.08-0.12 in. (2-3 mm). The open space between the closed-end wrench and caliper housing must be large enough to allow the adjuster to rotate without interference. ACAUTION ‘06195 Do not use power tools or an open-end wrench Figure 7 — Range of Movement on the hex nut (2) on the adjuster. Do not forcibiy rotate the adjuster. NOTE The rotation angle of the closed-end wrench will decrease with increasing adjustments. If the closed-end wrench does not rotate at all, only rotates during the first application of the brake, or rotates and then retracts to neutral, then the adjuster is defective. 4. If the adjuster is defective, replace the brake as described under “BRAKE CALIPER, ASSEMBLY REPLACEMENT” on page 27. 5. After checking the adjuster, set the air gap to 0.04 in. (1 mm) as desoribed under “Installing the Brake Pads" on page 23. 6. Reinstall the rubber plugs (1) and ensure proper seating in the caliper. 05194 Figure 6 — Hex Nut on the Adjuster Page 19«i REPAIR INSTRUCTIONS Checking the Brake Pads NOTE The brake pad thickness is to be checked regularly depending on operating conditions during maintenance intervals, and in accordance with applicable local laws and regulations. Bumed, glazed or oll-contaminated brake pads must be replaced immediately. Always replace brake pads on a per axle basis. BRAKE PAD REPLACEMENT Removing the Brake Pads 1. Disconnect the wear indicator cable at the plug. 2, Loosen and remove the hex-head bolt (2) on the hold-down strap (3). Refer to Figure 8. 3, Pull the hold-down strap (3) out of the brake caliper (1). 4, Remove the two hold-down springs (4). ACAUTION To avoid damage to the brake disc, the brake pads must be replaced as soon as one of the pads has reached its wear limit at any one poi 1. Replace only the pads as described in “BRAKE PAD REPLACEMENT” on page 20. 2. After checking the brake pads, reposition the cable guide (2), insert the hold-down springs (6) and secure the hold-down strap (4) with a hox-head bolt (3). Refer to Figure 4. Tighten the hex-head bolt to the specified torque (see "BRAKE SPECIFICATIONS” on page 48). Page 20 Figure 8 — Removing the Hold-Down Strap 5, Remove the cable guide (2) and contacts from the brake pads. Refer to Figure 9, 6. Remove the spring clip (1) from the brake caliper. Refer to Figure 9.> REPAIR INSTRUCTIONS 8. Slide the caliper by hand toward the cylinder side, Inspect the dust caps (1) and adjuster screw thrust cups for damage and ensure proper seating. Refer to Figure 11. Replace defective dust caps and thrust cups as described in “Replacing the Dust Caps and Adjuster Screw Thrust Cups” on page 35, Figure 8 — Removing the Spring Clip 7. Remove both brake pads (1, 2) from the brake. Refer to Figure 10. ACAUTION a The brake should not be actuated while the brake - ; re pads are removed. Figure 11 — Inspecting the Dust Caps so6tas Figure 10 — Removing the Brake Pads Page 21a 9. Remove one rubber plug (1). Refer to Figure 12. 10. Using a closed-end wrench, turn the hex nut (2) on the adjuster screw counterclockwise until it stops. Then, loosen the hex nut 1/4 turn. ACAUTION Do not use a power tool or an open-end wrench. REPAIR INSTRUCTIONS 11. Using a wire brush, remove any corrosion from the brake pad guide surfaces. ACAUTION Take care not to damage the dust caps (1, 2). Refer to Figure 13. The guide surfaces must be free of grease. Do not overtighten the hex nut (2) on the spindle. Ee soezo0b re Figure 12 — Adjusting the Hex Nut Figure 13 — Checking Dust Caps Page 22REPAIR INSTRUCTIONS Inspecting the Dust Caps and Checking Brake Caliper Movement 1, Move the brake caliper (1) by hand over the entire displacement distance. Refer to Figure 14, ACAUTION Keep hands and fingers out of the Inside of the caliper to avoid injury. Do not squeeze the guide pin dust caps against the torque plate. sect Figure 14— Brake Caliper Range of Movement 2. Inspect the dust caps (1) of the guide pins (2) for damage and proper seating within the grooves. Refer to Figure 15. 3. Check the brake caliper (3) for free movement. If the caliper does not move ‘neely, the quide bushings and dust caps must be replaced. 4, Replace the dust caps and guide bushings according to the procedures described in “SEAL REPLACEMENT” on page 30. 5. Check brake disc thickness and runout according to the procedure desoribed in “BRAKE DISC REPLACEMENT" on page 39, Figure 15 — Inspecting the Dust Caps Installing the Brake Pads 1, Slide the brake caliper until there is sufficient room between the caliper and brake dise on the wheel side to allow insertion of the brake pad. Refer to Figure 16. 2. Insert the new brake pad (2) on the wheel side, 3. Push the brake caliper toward the brake disc until the brake pad (2) makes contact with disc. 4. Insert the new brake pad (1) on the actuation side. Page 23aie REPAIR INSTRUCTIONS ACAUTION Do not overtighten the hex nut (1) on the adjuster spindle, NOTE Do not install the hold-down strap before the air gap has been set. 6. Install a new spring clip (1) in the brake caliper. Refer to Figure 18. 7. Install a new pre-assembled wear indicator and cable guide (2), and insert the sensor contacts into the brake pads. ACAUTION The sensor contacts must be pointed in the eee ee eee direction of the brake disc and the contacts must be properly seated. 5. Insert a 0.04 in. (1 mm) thick feeler gauge between the backing plate of the brake pad on the wheel side and the brake caliper. ‘Turn the adjuster screw hex nut (1) with a closed-end wrench until both brake pads contact the brake disc. Refer to Figure 17. J Figure 18 — Installing Spring Clip and Cable Guide Figure 17 — Tightening the Adjuster Screw Hox Nut Page 24Pics REPAIR INSTRUCTIONS 8. Lift up the cable guide (2) lightly from the NOTE brake caliper and position two new hold- down springs (1) under the cable guide, on Route cables on the actuator side (see arrow) so top of the brake pads. Refer to Figure 20. that they do not rest on the brake. Refer to i . Figure 19, 9. Press the cable guide (2) into position against the brake caliper. Figure 19 — Routing Cable Through Cable Guide Figure 20 — Cable Guide Placement on the Caliper Page 25a REPAIR INSTRUCTIONS 10. Slide a new hold-down strap (1) in the ‘openings on the brake caliper. Then push downward so that the hold-down strap snaps between the radial comers of the hold-down springs. Refer to Figure 21. 14, insert a plug into the holder. 15, Install the cable tie. NOTE Mount the hold-down strap above the cables of the wear indicator. ‘seezo00 ‘on210% Figure 22 — Hold-Down Strap Hex Nut 16. Install new rubber plugs (1) in the opening of the brake caliper. Check and make sure that the wheel hub tums freely. Refer to Figure 23. Figure 21 — Mounting the Hold-Down Strap 11, Install a new hex-head bolt (2) in the brake caliper and tighten to the specified torque (see “Torque Specifications — Lb-Ft (Nem)” on page 48). Refer to Figure 22. 12. Connect the wear indicator cable plug to the mating end on the vehicle side. 13. Secure the end of the cable with a new cable clip (1). ogee Figure 23 — Rubber Plugs Page 26és REPAIR INSTRUCTIONS BRAKE CALIPER ASSEMBLY REPLACEMENT [_ Aeaution | Observe the differences between the left NOTE (illustration A) and right (llustration B) brake configurations. Refer to Figure 24. Do not The new brake is supplied as a pre-assembled interchange the left and right brakes on the unit. vehiole! = Oo TEE ™ secetzn Figure 24 — Left and Right Brake Configurations Page 27REPAIR INSTRUCTIONS On the front axle, the long guide pin (2) is always located in the back. Refer to Figure 25. On the rear axle, the long guide pin (2) is always located on the top. senza Figure 25 — Short (1) and Long (2) Guide Pins Page 28REPAIR INSTRUCTIONS Removing the Brake Caliper 1. lemove the brake pads as described in "BRAKE PAD REPLACEMENT” on page 20, 2. Remove the actuation chamber as described in “BRAKE CHAMBER REPLACEMENT” on page 44. 3. Loosen and remove the six mounting bolts, Remove the brake caliper by lifting off mount, Refer to Figuse 26, Figure 26 — Mounting Bolt 4. Check the brake disc as described in “BRAKE DISC REPLACEMENT” on page 39, Installing the Brake «Position the brake caliper over the brake disc and mount it to the axle. Tighten the hex-head bolts to the specified torque. Refer to "BRAKE SPECIFICATIONS" on page 48. 300000005 ‘onas60 Figure 27 — Tightening the Hex-Head Bolt 2. Install the brake pads as described in “BRAKE PAD REPLACEMENT" on page 20. 3. Install the brake chamber as described in "BRAKE CHAMBER REPLACEMENT’ on page 44, Page 29i) REPAIR INSTRUCTIONS SEAL REPLACEMENT Removing the Dust Caps and Guide Pins . Remove the brake pads as described in “BRAKE PAD REPLACEMENT" on page 20. 2, Remove the brake chamber as described in “BRAKE CHAMBER REPLACEMENT” on page 44. 3, Remove the brake caliper assembly as. described in “Removing the Brake Caliper’ on page 29. 4, To soparate the torque plate (4) from the brake caliper (1) begin by removing the covers (2) for guide pins (3) from the caliper (1). Use a chisel or other suitable tool. See Figure 28. NOTE Take care not to damage the cover bore in the housing. Figure 28 — Brake Caliper and Guide Pin Covers 5. Remove the guide pin bolts (1, 3) with an Allen wrench. See Figure 29. 6. Separate the torque plate (4) from the calipor (1). Be careful when moving the brake caliper assembly. It is heavy. Figure 29 — Removing the Guide Pins and Bolts, 7. Remove the guide pins (1) and pull the dust caps (3) out of the caliper (2). See Figure 30. 8. Clean the mating surfaces of the torque plate and the guide pins (1), See Figure 30. Page 30Figure 80 — Guide Pin Surfaces Replacing the Guide Bushings i Place the caliper (2) on a firm base with the ‘cover opening on top to allow access to the bushings (1). See Figure 31. Press the guide bushings (1) out of the caliper with driver PIN FL2598, Refer to “SPECIAL TOOLS” on page 52. Clean the bushing bores in the brake caliper housing, scot REPAIR INSTRUCTIONS 4. For the long guide pin (Figure 32), first press in bushing (A) with driver P/N FL2590 (L1 =2,1-0.01 in. [52.5-0.3 mm)) and then. bushing (B) with driver P/N FL2591 (L2=0.5-0.01 in, [13.5-0.3 mm) until the driver is seated. For driver specifications, refer to "SPECIAL TOOLS" on page 52. 5. Lubricate the glide surfaces and space between the bushings. 2500. YX ! | w T Figure 31 — Guide Pin Bushing Driver Figure 32 — Long Guide Pin Bushing Installation 6. For the short guide pin bushing (C), use driver PIN FL2592 (L3 = 0.9-0.01 in. (23-0.3 mm) and press in until seated. See Figure 33. 7. Lubricate the glide surface of the bushing. Figure 38 — Short Guide Pin Bushing Installation Page 31is) REPAIR INSTRUCTIONS Installing the Guide Pin Dust Caps 1. Clean the dust cap seats in the caliper. NOTE The dust cap seats must be free of grease. 2, Insert new dust caps (2) in the seats (see arrow) of the brake caliper (1). See Figure 34, NOTE Make sure that the dust caps are properly seated, without creases, within the seats of the brake caliper. 8. Lubricate the glide surfaces of the new guide pins (1). See Figure 35. 4, Insert new guide pins from the cylinder side into the brake caliper (1), through the dust cap lip, and push the dust cap (2) against the guide pin seat. See Figure 34 and Figure 35, NOTE The long guide pin is a fitted pin and the short guide pin is a clearance pin. Move the guide pins back and forth several times to check for ease of movement. Refer to Figure 35. Ww Figure 34 — Guide Pin Dust Cap Installation Figure 35 — Installing the Guide Pin Page 32> REPAIR INSTRUCTIONS 5. Remove alll excess grease. 6. Position the torque plate (4) on the brake caliper (2) and insert the guide pins in the ACcAuTION flange (collar). Refer to Figure 37. 7. Insert new bolts (1) (long for fitted pin), (short for clearance pin) through the guide pins in the brake caliper (2), and tighten to the specified torque values. See Figure 37. The brake cartier end of the guide pins (1) (arrow) and the mating surfaces of the carrier must be free of grease. Refer to Figure 36. Do not lose the metal-ring on the dust cap (2) NOTE First secure the long fitted guide pin (1), then the short clearance guide pin (2) (see Figure 38). ACAUTION During assembly, take care not to damage or twist the dust caps while tightening the bolts. If guide pins are loosened during service, new bolts (1, 3) must be used to reassemble the brake. onze Figure 36 — Guide Pin Seating and Dust Cap Figure 37 — Installing the Guide Pin Bolts, Page 33ds REPAIR INSTRUCTIONS 8. Move the brake caliper back and forth several times on the guide pins (1, 2). The caliper must move freely. Refer to Figure 38. 9. Lubricate the cover openings in caliper (1). See Figure 39. 10. Insert new covers (2, 3) into the brake caliper (1) openings. Use a suitable tool to press the covers in until seated. ACAUTION Press the long cover (2) on the long guide pin side, and press the short cover (3) on the short guide pin side. Refer to Figure 39. NOTE Take care to avoid damaging the covers. ACAUTION Do not squeeze guide pin dust caps against 5 é (LONG) Z| Ot ICEL ty 2, a (SHORT) ‘s98220 Figure 38 — Guide Pin Movement Page 34 Figure 39 — Guide Pin Coversce REPAIR INSTRUCTIONS 11. Install the brake caliper assembly to the axle as described in “BRAKE CALIPER: ASSEMBLY REPLACEMENT" on page 27. 12, Install the brake pads and set the air gap as described in "BRAKE PAD REPLACEMENT” on page 20. 13. Install the brake chamber as described in “BRAKE CHAMBER REPLACEMENT” on page 44. Figure 40 — Installing the Brake Assembly Replacing the Oust Caps and Adjuster Screw Thrust Cups NOTE When only the dust caps with thrust cups need to be replaced, the brake chamber and brake caliper do not have to be removed. REMOVAL OF THE DUST CAPS WITH THRUST CUPS 1. Remove the brake pads as described in “BRAKE PAD REPLACEMENT” on page 20. 2. Push the brake caliper by hand toward the chamber. 3. Using two flat-tipped screwdrivers, remove the thrust cups from the seat in the adjuster screws. Refer to Figure 41. Figure 4% — Removing the Thrust Cups. Page 35,> 4, Remove two dust caps (1) from the seat in the brake caliper with a screwdriver. Refer to Figure 42. AcaurTion Take care not to damage the dust cap seats in the caliper housing. REPAIR INSTRUCTIONS s0e2atb Figure 42 — Dust Cap Seats in the Caliper INSPECTING THE THREADS OF THE ADJUSTER SCREWS, 1. With a closed-end wrench, loosen the adjuster screws approximately 1.2 in. (80 mm). Refer to Figure 43. 2. Inspect the threads for damage and corrosion while the screws are being tumed. 3. Clean all the seats (see arrows), secon Figure 43 — Adjuster Screw Threads 4. Lubricate threads, the mating surfaces and the bores of the adjuster screws (see arrow). Partially screw in the adjuster screws. ACAUTION The dust caps can be replaced if no dirt or water has penetrated into the brake caliper, or if the dust caps have been directly damaged during brake service. If in doubt, the brake has to be replaced as described in “BRAKE CALIPER ASSEMBLY REPLACEMENT” on page 27 if internal parts are corroded. sos2asb Figure 44 — Adjuster Screw Bore Page 36ies) REPAIR INSTRUCTIONS INSTALLING THE DUST CAPS WITH THRUST. cups After the brake caliper is installed, use only the preassembled new dust cap (1) with new thrust cup. Refer to Figure 45. 1. Before the dust caps are installed, make sure the seats are free of grease. 2. Center the dust cap (1) over the adjuster screw and press the dust cap into the seat by hand. Refer to Figure 46. 3. Visually inspect the dust cap for proper seating. Figure 45 — Dust Cap with Cup scons Figure 46 — Installing Dust Cap Page 37REPAIR INSTRUCTIONS 4. Press the thrust cups into the seat in the 5. Install brake pads and set the air gap as described in "BRAKE PAD REPLACEMENT” adjuster screw. Refer to Figure 47. on page 20. Refer to Figure 48. ACAUTION The thrust cups must be seated with a clicking noise. NOTE Make sure that the two dust caps are properly seated and free of folds, Figure 48 — Brake Caliper Assembly Installed Figure 47 — Dust Caps in the Brake Caliper Page 38pa REPAIR INSTRUCTIONS BRAKE DISC REPLACEMENT Inspecting the Brake Disc Measure the disc thickness in the area that contacts the brake pads. Inspect the brake disc for cracks and surface condition. \f wear limit values have been reached or exceeded, replace the brake disc as described below. NOTE Replacement of brake discs must always be performed on a per axle basis. Never replace only one disc on an axle. 2. Clean contamination from the tone ring with a wire brush. ACAUTION ‘A damaged or badly corroded tone ring can cause poor ABS function. Therefore, if damage or bad corrosion is found on the tone ring, replace the tone ring. See Rear Axle Service Manual, MV13-102, for proper procedures. CHECKING BRAKE DISC FOR WARPAGE/ RUNOUT 1, Mount the dial indicator on the torque plate of the brake so that the indicator is 1.4 in. (5 mm) from the top of the disc. See Figure 50. 1. If the brake disc is equipped with an integrated ABS tone ring, check the functioning of the ABS system. Refer to Figure 49. Figure 49 — Tone Ring Figure 50— Measuring Run-Out 2. With the brake disc installed, check run-out by turning the disc. Take several run-out measurements to ensure an accurate reading is obtained. 3. If the run-out measured is higher than 0.006 in, (0.15 mm), replace the brake disc. Page 39REPAIR INSTRUCTIONS Replacing the Brake Disc ACAUTION Its generally recommended that, upon installation of a new brake disc or after the disc has been machine tumed, new brake pads be installed, REMOVAL OF THE FRONT AXLE BRAKE Disc 1. Remove the brake pads as described in “BRAKE PAD REPLACEMENT” on page 20. 2. Remove the brake chamber as described in “BRAKE CHAMBER REPLACEMENT” on page 44, 3. Remove the brake from the axle as described in "BRAKE CALIPER ASSEMBLY REPLACEMENT" on page 27. 4. Secure the hub to prevent it rom turning, 5. Remove the mounting bolts. Refer to Figure 51. 6. Remove the hub. 7. Remove the brake disc using two M14 jackscrews. See Figure 52. ACAUTION Do not use a hammer or similar too! to remove the brake disc as this could damage the ABS sensor. Figure 61 — Mounting Bolts Page 40 Figure 52 — Jackscrews on the Brake Dise INSTALLING THE FRONT AXLE BRAKE DISC 1. Clean corrosion from the pilot bore and spindle with an abrasive cloth 2. Lift a new brake disc onto the wheel bearing spindle and tum it until the mounting holes are aligned. See Figure 53. 3. Align the hub, insert the mounting bolts and tighten to the specified torque values (see Front Axle Service Manual, MV12-102).REPAIR INSTRUCTIONS ‘Figure 53 — Installing the Hub 4. Adjust the ABS sensor. 5. Check the installed brake disc for maximum run-out. 6. Mount the brake as described in “BRAKE CALIPER ASSEMBLY REPLACEMENT” on page 27. 7. Install the brake pads as described in "BRAKE PAD REPLACEMENT” on page 20. 8. Install the brake chamber as described in “BRAKE CHAMBER REPLACEMENT” on page 44. REMOVAL OF THE REAR AXLE BRAKE DISC 1, Remove the brake pads as described in “BRAKE PAD REPLACEMENT” on page 20. 2, Remove the brake chamber as described in "BRAKE CHAMBER REPLACEMENT” on page 44, 3, Remove the brake assembly from the axle as described in "BRAKE CALIPER ASSEMBLY REPLACEMENT” on page 27. 4, Secure the hub to prevent it from turning. Figure 54— Hub and Dise Brake 5. Remove the hub with the brake disc according to the applicable rear axle service manual (MV13-101 or MV13-102). See Figure 55. ACAUTION Do not knock out the whee! bolts with the hub installed. Damage to the ABS sensor can result. See Figure 54. Figure 55 — Removing the Hub Page 41as REPAIR INSTRUCTIONS 6. Knock out the wheel bolts. See Figure 56, INSTALLING THE REAR AXLE BRAKE DISC NOTE NOTE Make sure to avoid damaging the threads. tf studs are damaged, they must be replaced. snot Figure 86 — Wheel Mounting Studs Page 42 Before installing a new or reworked disc, check the retaining ring and replace if necessary (see the applicable rear axle service manual, MV13-101 or MV13-102). 1. Clean corrosion from the pilot bore and the wheel bearing (see arrows) with an abrasive cloth. See Figure 57. Figure 57 — Pilot Bore and Wheel Bearinga REPAIR INSTRUCTIONS 2. Position a new brake disc on the hub and 4. Install the hub and brake disc as described turn ito line up the mounting holes. in the applicable rear axle service manual, 3. Install the whee! mounting bolts in the hub. eae neeeeaaues Install a nut and washer on the bolt and tighten in a crosswise pattern to eliminate any gap between the disc surfaces. See Figure 58. ACAUTION Do not knock the wheel bolts in with a hammer as the hub, brake disc or wheel bolts could be damaged! Figure 59— Installing the Hub 5. Remove oil or other preservatives from the brake disc. Adjust the ABS sensor, Inspect the newly installed brake disc for run-out. Install the brake as described in “BRAKE CALIPER ASSEMBLY REPLACEMENT" on page 27. . Install the brake pads as described in “BRAKE PAD REPLACEMENT” on page 20. 10. Install the brake chamber as described in “BRAKE CHAMBER REPLACEMENT” on page 44, No 2 Figure 58 — Mounting Bolts o Page 43pes) BRAKE CHAMBER REPLACEMENT Removing the Brake Chamber 1. Bleed all air from the air system. 2. Disconnect the airline from the brake chamber using the quick release tool. See “SPECIAL TOOLS’ on page 52. 3. Remove the brake chamber from the brake caliper by removing nuts (1) and pulling chamber from mount. See Figure 60. Figure 60 — Chamber Removal Installing the Brake Chamber ACAUTION Depending on the brake configuration, only the lowest drainage opening on the brake chamber can be open. 1. Before mounting the brake chamber, clean the sealing surface of the brake caliper and lubricate the spherical indentation (see arrow) on the brake lever. See Figure 61 REPAIR INSTRUCTIONS Figure 61 — Indentation on the Brake Lever 2. Position the brake chamber on the brake caliper and tighten the nuts with a wrench in a crosswise pattern, according to torque values specified by the chamber manufacturer. See Figure 62. Figure 62 — Installing the Brake Chamber Page 44REPAIR INSTRUCTIONS 8. Connect the air line to the chamber. ACAUTION Do not remove a brake chamber with air lines connected. Air hoses could be damaged. NOTE The brake line must not be twisted and must be routed so that it will not rub against any part of the vehicle. 7. Loosen and remove the hex-head bolts, then remove the brake chamber from the The brake line must also not interfere in any way brake caliper. See Figure 64. with movement of the brake caliper. 4, Check the air line connection for leaks and correct if necessary, 5. Perform functional and performance tests to ensure proper installation, Removing the Spring-Loaded Chamber 1. Block the vehicle to prevent rollaway. 2. Release the hand brake. 3. Turn the mechanical release (1) on the brake chamber counterclockwise to retract the brake. Refer to Figure 63. 4. Set the hand brake. 5. Mark both air lines (2) for correct reinstallation. 6. Disconnect the air lines (see Figure 63) using the quick release tool (refer to "SPECIAL TOOLS” on page 52). Figure 64 — HexHead Bolts Figure 63 — Air Line Connections Page 45REPAIR INSTRUCTIONS Installing the Spring-Loaded Chamber - L ACAUTION Depending on the brake configuration, only the lowest drainage opening on the brake chamber must be open! 1. Before installing the brake chamber, clean the sealing surface of the brake caliper and lubricate the spherical indentation (see arrow) of the brake lever. Refer to Figure 65, ‘ones Figure 65 — Indentation on the Brake Lever 2. Position the brake chamber on the brake caliper, install the mounting nuts and tighten with a wrench following a crosswise pattern. Tighten the nuts to the torque values specified by the chamber manufacturer. 3. Connect both brake lines (2) to the brake chamber and tighten. Refer to the marks (11 and 12) on the brake chamber for correct installation. NOTE Make sure that the brake lines are connected property. Port 11 = Service/Foot Brake (Larger Line) Port 12 = Parking/Hand Brake (Smaller Line with GreenWhite Band) 4, Release the hand brake. 5. Turn the mechanical release (1) on the chamber clockwise to reengage the brake. PonT #11 — LARGER LINE PORT #12— SMALLER LINE WITH GREENWHITE BAND Figure 66 — Air Line Connections 6. Check all air connections for leaks and correct if necessary. NOTE The brake lines must not be twisted and must be routed so that they will not rub against any part of the vehicle, The brake lines also must not interfere in any way with movement of the brake caliper. 7. Perform functional and performance tests to ‘ensure proper installation Page 46és SPECIFICATIONS SPECIFICATIONS Page 47ais SPECIFICATIONS BRAKE SPECIFICATIONS Torque Specifications — Lb-Ft (Nem) Figure 67 — Brake Caliper Assembly Torque Specifications Page 48SPECIFICATIONS Brake Disc and Pad Material Specifications oan. no) TEXTAR] T3016 1 T 1 i i i i i ' i ! ' 4 1 1 Il 1 1 i o3N. (mm) 1.21N. (a0 mm) 19m! (35 wy 151M, iss uni | 3mN, conn 214.81. (e375) S (5mm) em o 0.006 IN. (0.15 MM) sosteeb Figure 68 — Brake Disc and Pad Material Specifications. Page 49as Symbols SPECIFICATIONS © Wear iit Rotational force left bad bs (Nem) Page 50 Figure 69 — Symbol Use Chartés SPECIAL TOOLS & EQUIPMENT SPECIAL TOOLS & EQUIPMENT Page 51SPECIAL TOOLS & EQUIPMENT SPECIAL TOOLS Specifications Tool Reference No. Designation Usage FL2500 Driver Refer to “Replacing the Guide Bushings” on page St. FL251 Driver fer to "Replacing the Guide Bushings” on page 31. FL2502 Driver Refer to “Replacing the Guide Bushings” on page 31, FL2588 Driver Refer to "Replacing the Guide Bushings" on page 31 15000262464 (kit) Quick Release Tool Refer to “BRAKE CHAMBER REPLACEMENT” on page 44, Page 52a TOOL PRINTS SPECIAL TOOLS & EQUIPMENT To manufacture drivers locally, refer to the specifications below. 0.86 IN (22505 um) eos 2.071N. 2.631N. 007 N. (62.5 25MM) 07 = Miy——"| 0 Da 45° 1.631. (avs mn) 1.451N, = }— +} (270 73,¥in au77m, (0150.2 him FL2590 0.5918. oe. 195-3) worn (22.05 um) nw) x45" > 1631N. (534mm) san | 77. o'2 jo cain Flas 0.9951. 0.06 N. | _ [423 an a42iN, 07 N. 2205mm[~ ]* “67 = ny (MM) x45" 77. (015202 mim) Fi2502 0.86 IN. Le phe 4721N, »|oo7m. (222051m) (120 23 tiny (any x 45° 1.45 1N, ° T (7.03, ee TY] 7452.8) F258 sues ire 70 — Driver Specifications Page 53> NOTES Page 54INDEX INDEX Page 55> INDEX A ° ADVISOHV/UABENS fete Teer te 2) | OPERATION | nea +10 B R BRAKE CALIPER ASSEMBLY REMOVING THE BRAKE CALIPER ........29 REPLACEMENT ........ :+s+::27 REMOVING THE BRAKE CHAMBER ......44 BRAKE CHAMBER REPLACEMENT .......44. REMOVING THE BRAKE PADS............ 20 BRAKE CHECKS .... -++::18 REMOVING THE DUST CAPS AND. BRAKE DISC AND PAD MATERIAL GUIDE PINS . od SPECIFICATIONS ......0...++.s0664-49 REMOVING THE SPRING-LOADED BRAKE DISC REPLACEMENT . eee eso) CHAMBER .....-. 0... 5 245 BRAKE PAD REPLACEMENT ... 1:20 REPLACING THE BRAKE DISC -40 BRAKE SPECIFICATIONS ... /.48 REPLACING THE DUST CAPS AND ADJUSTER SCREW THRUST CUPS .............35 Cc REPLACING THE GUIDE BUSHINGS .. . 31 CHECKING THE AIR GAP eee AB s CHECKING THE AUTOMATIC ADJUSTER .....- ween ND SAFETY INFORMATION ae CHECKING THE BRAKE PADS | vee 20 SAFETY TIPS TO BE CONSIDERED | COMPONENT LOCATIONS ..............14 DURING REPAIR .............. 6 CONVERSION CHART ..............- 6 SEAL REPLACEMENT ..................30 SERVICE PROCEDURES AND D TOOL USAGE . 3 SPECIAL TOOLS .... . . ee 52 Cee ee a SPECIFICATIONS ......... ete eee 1 SYMBOLS ...... ceee eee BO INSPECTING THE BRAKE DISC . eee BD T INSPECTING THE DUST CAPS AND TORQUE 6PECIFCATIONS — MOVEMENT ... 23 LB-FT (NM) 0... INSTALLING THE BRAKE ...... pert || INSTALLING THE BRAKE CHAMBER 2 44 INSTALLING THE BRAKE PADS ..........23 INSTALLING THE GUIDE PIN [eT ge! i ees +. 82, INSTALLING THE ‘SPRING LOADED CHAMBER . eee eee 46 Page 56DISC BRAKE SERVICE FOR WABCO PAN 19 SERVICE MANUAL FREEDOM™ MEDIUM DUTY TRUCKS @ MACK TRUOKS, INC. 2003