BENDIX® SPLINED DISC® HUB ROTOR REPLACEMENT FOR BENDIX® ADB22X™ & ADB22X-V™ AIR DISC BRAKES Drive Hub Wheel Studs 1 Hub ID Label 2 3 Steer Hub Wheel 4 4 Studs Splined Disc Rotor on 1 Aluminum Drive Hub Hub ID ABS Tone Label Wheel & Fasteners 2 3 Kit Contents Item No. Description Qty. Intermediate Elements 1 20 (Spacers) 2 Spring Elements (Brackets) 10 ABS Tone 3 Collar Screws 10 Wheel (press on) Splined Disc Rotor on Rotor Aluminum Steer Hub 4 1 (Included in Rotor kits only) Figure 1 – Bendix® Splined Disc® Rotor Examples (Exploded Views) GENERAL SPLINED DISC® HUB ROTOR IDENTIFICATION These instructions cover the installation of the intermediate Splined Disc® Hub Rotors are designed to assist vehicle elements (1), spring elements (2), collar screws (3) and the maintenance by typically allowing the rotor to be serviced rotor (4), where applicable. Also covered, is the installation without requiring the entire hub/rotor assembly be replaced. of the air disc brake pads which Bendix recommends replacing when a rotor is replaced. For vehicles with wear sensors and/or electronic wear diagnostic equipment, consult the Service Data sheet SD-23-7541 available on bendix.com or foundationbrakes.com. 1 GENERAL SAFETY GUIDELINES WARNING! PLEASE READ AND WARNING: Not all wheels and valve stems are compatible with Bendix® air disc brakes. Use only FOLLOW THESE INSTRUCTIONS wheels and valve stems approved by the vehicle TO AVOID PERSONAL INJURY OR DEATH: manufacturer to avoid the risk of valve stem shear When working on or around a vehicle, the following and other compatibility issues. guidelines should be observed AT ALL TIMES: ▲P ark the vehicle on a level surface, apply the parking WARNING: AVOID CREATING brakes and always block the wheels. Always wear personal DUST. POSSIBLE CANCER AND LUNG protection equipment. DISEASE HAZARD. ▲Stop the engine and remove the ignition key when working under or around the vehicle. When working in the engine While Bendix Spicer Foundation Brake LLC (BSFB, compartment, the engine should be shut off and the ignition Bendix) does not offer asbestos brake linings, the key should be removed. Where circumstances require that long-term effects of some non-asbestos fi bers have the engine be in operation, EXTREME CAUTION should be not been determined. Current Occupational Safety used to prevent personal injury resulting from contact with and Health Administration (OSHA) Regulations moving, rotating, leaking, heated or electrically-charged cover exposure levels to some components of components. non-asbestos linings, but not all. The following ▲D o not attempt to install, remove, disassemble or precautions must be used when handling these assemble a component until you have read, and thoroughly materials. understand, the recommended procedures. Use only the ▲ Avoid creating dust. Compressed air or dry proper tools and observe all precautions pertaining to use brushing must never be used for cleaning brake of those tools. assemblies or the work area. ▲I f the work is being performed on the vehicle’s air brake ▲ Bendix recommends that workers doing brake system, or any auxiliary pressurized air systems, make work must take steps to minimize exposure certain to drain the air pressure from all reservoirs before to airborne brake lining particles. Proper beginning ANY work on the vehicle. If the vehicle is procedures to reduce exposure include working equipped with a Bendix® AD-IS® air dryer system, a Bendix® DRM™ dryer reservoir module, or a Bendix® AD-9si® air in a well-ventilated area, segregation of areas dryer, be sure to drain the purge reservoir. where brake work is done, use of local fi ltered ▲ Following the vehicle manufacturer’s recommended ventilation systems or use of enclosed cells with procedures, deactivate the electrical system in a manner fi ltered vacuums. Respirators approved by the that safely removes all electrical power from the vehicle. Mine Safety and Health Administration (MSHA) ▲N ever exceed manufacturer’s recommended pressures. or National Institute for Occupational Safety and Health (NIOSH) should be worn at all times ▲N ever connect or disconnect a hose or line containing during brake servicing. pressure; it may whip and/or cause hazardous airborne dust and dirt particles. Wear eye protection. Slowly open ▲ Workers must wash before eating, drinking or connections with care, and verify that no pressure is smoking; shower after working, and should not present. Never remove a component or plug unless you are wear work clothes home. Work clothes should certain all system pressure has been depleted. be vacuumed and laundered separately without ▲ Use only genuine Bendix® brand replacement parts, shaking. components and kits. Replacement hardware, tubing, hose, ▲ OSHA Regulations regarding testing, disposal fi ttings, wiring, etc. must be of equivalent size, type and of waste and methods of reducing exposure strength as original equipment and be designed specifi cally for asbestos are set forth in 29 Code of Federal for such applications and systems. Regulations §1910.001. These Regulations ▲C omponents with stripped threads or damaged parts should provide valuable information which can be be replaced rather than repaired. Do not attempt repairs utilized to reduce exposure to airborne particles. requiring machining or welding unless specifi cally stated ▲ Material Safety Data Sheets on this product, as and approved by the vehicle and component manufacturer. required by OSHA, are available from Bendix. ▲P rior to returning the vehicle to service, make certain all Contact the Bendix Tech Team at 1-800-247-2725, components and systems are restored to their proper option 2, or [email protected]. operating condition. ▲ For vehicles with Automatic Traction Control (ATC), the ATC function must be disabled (ATC indicator lamp should be ON) prior to performing any vehicle maintenance where one or more wheels on a drive axle are lifted off the ground and moving. ▲T he power MUST be temporarily disconnected from the radar sensor whenever any tests USING A DYNAMOMETER are conducted on a vehicle equipped with a Bendix® Wingman® system. ▲Y ou should consult the vehicle manufacturer's operating and service manuals, and any related literature, in conjunction with the Guidelines above. 2 INSPECTION Periodic inspection of the Bendix® Splined Disc® rotor attachment hardware is recommended to ensure optimum Follow all standard safety procedures including, but not braking performance. Bendix recommends verifying limited to, those on page 2 of these instructions. Also the torque on the spring element fasteners whenever read the vehicle manufacturer's recommendations. a brake inspection is performed. Please refer to When working on foundation brakes, be sure that the SD-23-7541 for Bendix® ADB22X™ air disc brake inspection vehicle is on level ground, that the vehicle is parked interval recommendations. by other means than the foundation brakes, and that the wheels are chocked. When installing pads, where In situations where the entire hub/rotor assembly is to appropriate, use heavy duty gloves and always keep be replaced, follow the vehicle manufacturer's guidelines fingers away from potential pinch hazard areas. for replacement. Additionally, Bendix recommends that the wheel seal also be replaced at the same time, using Bendix air disc brakes are precision-engineered braking a high temperature seal. Follow the wheel seal and/ mechanisms. The “friction couple” braking characteristics or vehicle manufacturer's guidelines for full installation have been carefully optimized and the rotor design and instructions. Adjust the bearings and refill the bearing materials have been matched with special formulation oil to the vehicle manufacturer's specifications. brake pads for optimal performance, therefore use only genuine Bendix® brand parts and brake pads. When replacing a splined disc rotor, Bendix strongly recommends that the brake pads be replaced (as an axle set.) Call the Bendix Tech Team at 1-800-AIR-BRAKE (1-800-247-2725 option 2) for the appropriate brake pad kit. Rotor replacement necessitates the removal of the pads. Pad Retainer Pin Pad Retainer Bar Spring Clip Washer Pad Assembly Caliper Tappet and Boot Assembly Shear Adapter Tappet Bushing Adjuster Cap Figure 2 – Part Identification 3 Pin Pad Retainer Bar Washer Spring Clip Figure 3 – Brake Pad Removal Caliper Inboard Outboard 23 37 Adjuster 23 Inboard Pad Shear Adapter 37 Brake Pad Assembly Adjuster Cap Figure 4 – Brake Pad Removal PAD REMOVAL in a counterclockwise direction (see Page 9). NOTE: Do not use an open-ended wrench as this may damage the When replacing brake pads, Bendix strongly recommends adapter. that the pads be replaced as an axle set. Refer to the vehicle manufacturer’s recommendations and release (or cage) the spring brakes and remove the wheel. Never turn the adjuster without the shear adapter NOTE: Before removing the brake pads it is strongly installed. The shear adapter is a safety feature and is recommended that the air disc brake adjuster mechanism designed to prevent an excess of torque from being be checked for correct operation (see Page 8). applied to the adjuster. The shear adapter is designed to break if excess torque is applied. See Figure 2 throughout the pad removal procedure. Remove the spring clip and washer, depress the pad If the shear adapter breaks, attempt a second time with retainer bar, and remove the pad retainer pin and pad a new (unused) shear adapter which is included in the retainer bar. Discard these four items – replacements brake pad kit. A second breakage of the shear adapter are included in the brake pad service kits. As necessary, indicates that the adjustment mechanism requires additional remove any in-pad wear sensor components and discard. inspection. Refer to Service Data sheet SD-23-7541 for additional adjuster troubleshooting information. Pull off the adjuster cap using the tab, taking care to keep the shear adapter in position on the adjuster. To remove the outboard brake pad, slide the caliper fully to the outboard position first.