TP-0759 Issued 06-07

Installing Caliper Bumper Gap Shims on All-Makes Hydraulic Service Parts Disc Brakes Instructions Kit E-6890

HazardTP-0759Issued1 Service 06-07 Parts Instructions Alert Messages Determine if Shims are Required Read and observe all Warning and Caution hazard alert messages in 1. Wear safe eye protection. this publication. They provide information that can help prevent 2. Park the vehicle on a level surface. Block the wheels to prevent serious personal injury, damage to components, or both. the vehicle from moving. WARNING 3. Remove the caliper assembly from the anchor plate. Remove To prevent serious eye injury, always wear safe eye protection the key retention bolt. Then tap out the key and spring. when you perform vehicle maintenance or service. 4. Use a wire brush to clean the v-way surfaces of the caliper and anchor plate. any deep nicks or gouges smooth. Park the vehicle on a level surface. Block the wheels to prevent the vehicle from moving. Support the vehicle with 5. Lay a straightedge across the caliper v-way surfaces. Use a safety stands. Do not work under a vehicle supported only by feeler to measure the gap. jacks. Jacks can slip and fall over. Serious personal injury and ț If the gap depth is 0.050-inch (1.27 mm) or more: damage to components can result. Replace the caliper. Figure 1.

ASBESTOS AND NON-ASBESTOS Figure 1

FIBERS WARNING CALIPER ASSEMBLY STRAIGHTEDGE Some brake linings contain asbestos fibers, a cancer and lung disease hazard. Some brake linings contain non-asbestos fibers, whose long-term effects to health are unknown. You must use caution when you handle both asbestos and non-asbestos materials. How to Obtain Kits FEELER Call ArvinMeritor’s Commercial Vehicle Aftermarket at GAUGE 4006582a 888-725-9355. Figure 1 Kit E-6890 Part Quantity 6. Install the caliper back into the anchor plate. Install a new production key and bolt, but do not install the support spring at ″ Shims — 0.025 (0.635 mm) Thick 2 this time. Shims — 0.045″ (1.143 mm) Thick 2 7. Insert a screwdriver into the center of the key-to-bumper gap. Support Keys 2 Pry firmly to ensure the caliper is seated against the three slide Support Springs 2 surfaces “A”, “B” and “D”. Figure 2. Figure 2 Install the Shim STEERING BUMPER KNUCKLE GAP 1. Remove the caliper assembly from the anchor plate. Install the selected shim on the anchor plate v-way opposite the key and “A” “D” spring v-way. Figure 3. SUPPORT KEY

“B” “C” Figure 3

ANCHOR SHIM SPRING BOLT PLATE STEERING V-WAY KNUCKLE KEY 4006583a

Figure 2 ANCHOR 8. Measure the bumper gap. Use the largest or stack PLATE of gauges that will fit into the gap on either side of the screwdriver. Figure 2. 4006584a

9. Use the bumper gap measurement to select a shim according Figure 3 to the table. 2. With the shim in place on the anchor plate v-way, reinstall the ț If the bumper gap exceeds 0.145-inch (3.683 mm): Replace the old caliper with a new caliper and remeasure caliper assembly with a new key and spring. the bumper gap. 3. Measure the bumper gap as described in Steps 7 and 8. If the gap exceeds 0.058-inch (1.473 mm), install a thicker shim or ț If the bumper gap with the new caliper is between 0.058-inch (1.473 mm) and 0.145-inch (3.683 mm): replace components as described in Step 9. Select a shim from the table. ț If the bumper gap with the new caliper exceeds 0.145-inch (3.683 mm): Replace the anchor plate also. Use a new key and spring when assembling the new components.

Gap Size Shim Thickness 0-0.058″ (0-1.473 mm) None required 0.058-0.101″ 0.025″ (0.635 mm) (1.473-2.565 mm) 0.101-0.145″ 0.045″ (1.143 mm) (2.565-3.683 mm) 0.145″ (3.683 mm) Refer to Step 9.

Meritor Heavy Vehicle Systems, LLC Information contained in this publication was in effect at the time the publication was approved for printing and is subject to 7975 Dixie Highway change without notice or liability. Meritor Heavy Vehicle Systems, LLC, reserves the right to revise the information presented or Florence, KY 41042 USA to discontinue the production of parts described at any time. 888-725-9355 Copyright 2007 TP-0759 www.meritorhvs.com ArvinMeritor, Inc. Issued 06-07 www.xpresswayplus.com All Rights Reserved Printed in USA (16579/22882)