4x60Hydraulic Dry Disc Brake

BSM-0460E SERVICE MANUAL

March 2019

Table of Contents

i

Table of ContentsService Notes ....................................................... ii

Asbestos and Non-Asbestos Fibers Warning ........ iii

Exploded View.......................................................1

Introduction ..........................................................2

Model Nomenclature ........................................2

Identifi cation ...................................................2

Inspection ............................................................3

Brake Pads ......................................................3

Brake Rotors ....................................................3

Piston Boots ....................................................3

Seals and Pistons .............................................3

Component Replacement ......................................4

Replace Brake Pads .........................................4

Remove Brake Assembly ..................................4

Replace Boots ..................................................5

Replace Pistons and Seals ...............................6

Install Brake Assembly .....................................8

Troubleshooting ...................................................9

Service Kits ....................................................... 10

Service Notes

ii

Service Notes

This service manual describes the service and repair procedures for the 4x60 Hydraulic Dry Disc Brake. The information contained in this manual is current at the time of publication and is subject to change without notice or liability.

Follow all company procedures when you service or repair equipment or components. Understand all instructions before performing any product service. Some procedures require the use of special tools for safe and correct ser-vice. Failure to use special tools when required can cause serious personal injury to service personnel, as well as, damage to equipment and components.

The instructions contained in this service manual are intended for use by skilled and experienced mechanics knowledgeable in the installation, repair, and replacement of the AxleTech product described herein.

! DANGERInstallation, maintenance, and replacement of such prod-ucts requires a high degree of skill and experience. The consequences of improper installation, maintenance, or replacement (including the use of inferior or substandard components) are grave and can result in product failure and resulting loss of control of the vehicle, possible injury or death of persons, and/or possible future or additional product damage.

AxleTech does not authorize anyone, other than highly skilled and experienced individuals, to attempt to utilize the instructions contained in this manual for the installa-tion, maintenance, or replacement of the product de-scribed herein, and AxleTech shall have no liability of any kind for damages arising out of (or in connection with) any other use of the information contained in this manual.

UpdatesFor the latest version of this manual, please visit AxleTech International’s web site at www.axletech.com.

NotationsAxleTech International uses the following notation to warn the user of possible safety problems and to provide information that will prevent damage to equipment and components:

! DANGERA DANGER indicates a procedure that you must follow exactly or it will cause death or serious injury.

! WARNINGA WARNING indicates a procedure that you must follow exactly or it may cause death or serious injury.

! CAUTIONA CAUTION indicates a procedure that you must follow exactly to avoid damaging equipment or components.

NOTEA NOTE indicates an operation, procedure, or instruction that is important for proper service. A NOTE can also supply information that will help to make service quicker and easier.

Asbestos and Non-Asbestos Fibers Warning

iii

Asbestos and Non-Asbestos Fibers Warning

OSHA* Toxic and Hazardous Substances 29 CFR 1910.1001

Work practices and engineering controls for automotive brake and clutch inspection, disassembly, repair and assembly -- Mandatory

This mandatory appendix specifi es engineering controls and work practices that must be implemented by the employer during automotive brake and clutch inspection, disassembly, repair, and assembly operations.

Proper use of these engineering controls and work practices by trained employees will reduce employees’ asbestos exposure below the permissible exposure level during clutch and brake inspection, disassembly, repair, and assembly operations. The employer shall institute engineering controls and work practices using either the method set forth in paragraph [A] or paragraph [B] of this appendix, or any other method which the employer can demonstrate to be equivalent in terms of reducing employ-ee exposure to asbestos as defi ned and which meets the requirements described in paragraph [C] of this appendix, for those facilities in which no more than 5 pairs of brakes or 5 clutches are inspected, disassembled, reassembled and/or repaired per week, the method set forth in para-graph [D] of this appendix may be used:

[A] Negative Pressure Enclosure/HEPA Vacuum System Method

(1) The brake and clutch inspection, disassembly, repair, and assembly operations shall be enclosed to cover and contain the clutch or brake assembly and to prevent the release of asbestos fi bers into the worker’s breathing zone.

(2) The enclosure shall be sealed tightly and thoroughly in-spected for leaks before work begins on brake and clutch inspection, disassembly, repair, and assembly.

(3) The enclosure shall be such that the worker can clearly see the operation and shall provide impermeable sleeves through which the worker can handle the brake and clutch inspection, disassembly, repair and assembly. The integri-ty of the sleeves and ports shall be examined before work begins.

(4) A HEPA-fi ltered vacuum shall be employed to maintain the enclosure under negative pressure throughout the op-eration. Compressed-air may be used to remove asbestos fi bers or particles from the enclosure.

(5) The HEPA vacuum shall be used fi rst to loosen the as-bestos containing residue from the brake and clutch parts and then to evacuate the loosened asbestos containing material from the enclosure and capture the material in the vacuum fi lter.

(6) The vacuum’s fi lter, when full, shall be fi rst wetted with a fi ne mist of water, then removed and placed immedi-ately in an impermeable container, labeled according to paragraph (j)(5) of this section and disposed of according to paragraph (k) of this section.

(7) Any spills or releases of asbestos containing waste material from inside of the enclosure or vacuum hose or vacuum fi lter shall be immediately cleaned up and dis-posed of according to paragraph (k) of this section.

[B] Low Pressure/Wet Cleaning Method

(1) A catch basin shall be placed under the brake assem-bly, positioned to avoid splashes and spills.

(2) The reservoir shall contain water containing an organic solvent or wetting agent. The fl ow of liquid shall be con-trolled such that the brake assembly is gently fl ooded to prevent the asbestos-containing brake dust from becom-ing airborne.

(3) The aqueous solution shall be allowed to fl ow between the brake drum and brake support before the drum is removed.

(4) After removing the brake drum, the wheel hub and back of the brake assembly shall be thoroughly wetted to suppress dust.

Asbestos and Non-Asbestos Fibers Warning

iv

(5) The brake support plate, brake shoes and brake com-ponents used to attach the brake shoes shall be thor-oughly washed before removing the old shoes.

(6) In systems using fi lters, the fi lters, when full, shall be fi rst wetted with a fi ne mist of water, then removed and placed immediately in an impermeable container, labeled according to paragraph (j)(4) of this section and disposed of according to paragraph (k) of this section.

(7) Any spills of asbestos-containing aqueous solution or any asbestos-containing waste material shall be cleaned up immediately and disposed of according to paragraph (k) of this section.

(8) The use of dry brushing during low pressure/wet clean-ing operations is prohibited.

[C] Equivalent Methods

An equivalent method is one which has suffi cient written detail so that it can be reproduced and has been demon-strated that the exposures resulting from the equivalent method are equal to or less than the exposures which would result from the use of the method described in paragraph [A] of CFR 1910.1001. For purposes of making this comparison, the employer shall assume that expo-sures resulting from the use of the method described in paragraph [A] of this appendix shall not exceed 0.016 f/cc, as measured by the OSHA reference method and as averaged over at least 18 personal samples.

[D] Wet Method

(1) A spray bottle, hose nozzle, or other implement capa-ble of delivering a fi ne mist of water or amended water or other delivery system capable of delivering water at low pressure, shall be used to fi rst thoroughly wet the brake and clutch parts. Brake and clutch components shall then be wiped clean with a cloth. Any wastewater generated must be captured and properly disposed of without allow-ing it to dry on any surfaces.

(2) The cloth shall be placed in an impermeable container, labeled according to paragraph (j)(4) of the standard and then properly disposed of as an asbestos waste, or the cloth shall be laundered in a way to prevent the release of asbestos fi bers in excess of 0.1 fi ber per cubic centimeter of air.

(3) Any spills of solvent or any asbestos containing waste material shall be cleaned up immediately according to paragraph (k) of this section.

(4) The use of dry brushing during the wet method opera-tions is prohibited.

[59 FR 40964, Aug. 10, 1994; 60 FR 33972, June 29, 1995; 77 FR 17778, March 26, 2012]

For more information, visit www.osha.gov, or call OSHA at 1-800-321-OSHA(6742), TTY 1-877-889-5627.

*References to OSHA, NIOSH, MSHA, and EPA, which are regulatory agencies in the United States, are made to provide further guidance to employers and workers em-ployed within the United States. Employers and workers employed outside of the United States should consult the regulations that apply to them for further guidance.

Exploded View

1

Exploded View

Item Description

1 Piston

2 Piston Seal

3 Piston Boot

4 Big Spiral Ring

5 Small Spiral Ring

6 Bleeder Cap

7 Bleeder Screw

8 Brake Caliper Housing Assembly

9 Brake Pad Retainer Pin

10 Cotter Pin

11 Brake Pad Retainer Spring

12 Brake Pad

9

10

11

12

8 76 5

43

21

Introduction

2

Introduction

The 4x60 hydraulic disc brake has a fi xed-mount split caliper (8) and four pistons (1) 60 mm diameter. The cylinder bores are sealed with four piston boots (3) held in place on the caliper housing by the big spiral ring (4) and on the piston by the small spiral ring (5). The brake pad retainer spring (11) is locked by the pad retainer pin (9) and cotter pin (10) and creates pressure against the brake pads (12) acting as anti-rattle spring.

The opposed pistons push against each other applying clamping force on the brake pads to create friction force against the brake rotor. As friction material wears, the pistons extend out of the cylinder bores and compensate for lining and rotor wear.

! DANGERUse the correct actuation fl uid. The brake will not work properly using the incorrect actuation fl uid.

Model Nomenclature

Identifi cationA = DOT3, DOT4, or DOT5.1 Brake FluidM = Mineral Oil

Six Digit Serial Number

Julian Manufacturing Date Code

A460100 12345630616

A = DOT3, DOT4, or DOT5.1 Brake FluidM = Mineral Oil

Exact Specification

Piston Diameter (mm)Number of Pistons

D = Disc Brake

H = Hydraulic

HDA-460-100

Inspection

3

Inspection

Brake pads (12), brake rotors, and piston boots (3) must be visually inspected at regular intervals, depending on vehicle usage. Hydraulic connections, bleeders, and pistons need to be checked for any signs of leakage. Check vehicle manual for recommended maintenance and inspection intervals.

Brake PadsReplace brake pads if you fi nd the following conditions:

• The lining thickness reaches 3.0 mm on any brake pad in any location.

• The linings are contaminated with brake fl uid, oil, or grease.

• The linings have large or deep cracks. Small, tight cracks or heat checks on the lining surface, which are caused by high temperatures, are normal.

! CAUTIONALWAYS REPLACE BRAKE LININGS ON BOTH WHEEL ENDS OF AN AXLE FOR MAINTAINING CORRECT BRAKE BALANCE. USE AXLETECH INTERNATIONAL BRAKE PADS FOR MAINTAINING THE BRAKE PERFORMANCE.

Brake RotorsReplace brake rotors if:

• Cracks through the rotor section or heavy heat checking are visible.

• Rotor thickness is less than the minimum value marked on the rotor.

• Rotor lateral runout of the braking surface is over 0.38 mm.

• Rotor thickness variation exceeds 0.03 mm.

Piston Boots• Replace piston boots if the boot material is hardened,

cracked, or has any visible damage.

• Inspect pistons and piston seals as they may also be damaged if boots are split.

• Inspect cylinder bores for damage or corrosion.

Seals and Pistons• Replace piston seals if any leaks are visible at the

pistons.

• Replace pistons if scratches, nicks, scoring, corrosion, wear, or any other damage is visible.

• Inspect caliper bores for scratches, nicks, scoring, corrosion wear, and damage.

• Replace brake caliper if any of these conditions exist.

Component Replacement

4

Component Replacement

! DANGERPARK THE VEHICLE ON A LEVEL SURFACE. BLOCK THE WHEELS TO PREVENT THE VEHICLE FROM MOVING. SUPPORT THE VEHICLE WITH SAFETY STANDS. DO NOT WORK UNDER A VEHICLE SUPPORTED ONLY BY JACKS. JACKS CAN SLIP AND FALL OVER. SERIOUS PERSONAL INJURY AND DAMAGE TO COMPONENTS CAN RESULT.

! WARNINGTO PREVENT SERIOUS EYE INJURY, ALWAYS WEAR EYE PROTECTION WHEN PERFORMING VEHICLE MAINTE-NANCE OR SERVICE.

! CAUTIONALWAYS REPLACE BRAKE LININGS ON BOTH WHEEL-ENDS OF AN AXLE FOR MAINTAINING CORRECT BRAKE BALANCE. USE AXLETECH INTERNATIONAL BRAKE PADS FOR MAINTAINING THE BRAKE PERFORMANCE.

NOTE: See “Exploded View” for component details.

Replace Brake Pads• Park the vehicle on a level surface. Block the wheels

to prevent the vehicle from moving. Raise the vehicle and support with safety stands.

• Remove the wheel and tire assembly according to the vehicle manufacturer’s recommendation.

• Remove the master cylinder reservoir fi ller cap. Check the brake fl uid level in the reservoir. If necessary, remove fl uid to keep the reservoir from overfl owing when compressing the pistons into the caliper.

• Remove the cotter pin (10), push the brake pad retainer spring (11) against the brake pads, and slide out the brake pad retainer pin (9).

• Remove the brake pad retainer spring (11).

• Push brake pads away from the rotor using a fl at screwdriver or pry bar until the pistons are all the way in the caliper. Care should be taken not to cut the boot.

• Slide brake pads (12) out.

• Inspect piston boots (3) and replace if the rubber is hardened, cracked, or damaged.

• Inspect pistons (1) for any leaks.

• Slide new brake pads (12) in place.

• Inspect brake pad retainer spring (11) and brake pad retainer pin (9) for any fracture or damage and replace if necessary. Install brake pad retainer spring (11) and press against the brake pads (12) to install brake pad retainer pin (9). Install a new cotter pin (10).

• Install the wheel and torque wheel nuts or wheel studs to the vehicle manufacturer’s recommended torque.

• Install master cylinder reservoir fi ller cap.

• Actuate the brake several times for adjusting the brake pads to the rotor.

• Check the brake fl uid level in the reservoir and add brake fl uid if necessary. Use the correct brake fl uid type recommended by the vehicle manufacturer.

Remove Brake Assembly• Remove brake pads as described in the “Replace

Brake Pads” section.

• Disconnect the hydraulic line from the caliper inlet port.

! CAUTIONNEVER LOOSEN OR REMOVE THE FOUR SCREWS JOIN-ING THE TWO CALIPER HALVES TOGETHER.

NEVER LOOSEN OR REMOVE THESE 4 BOLTS

• Remove the two M18 caliper mounting screws that bolt the caliper to the knuckle or brake bracket.

NOTE: Make a note where the shoulder bolt is located for installing it in the same location.

• Drain the fl uid from the caliper.

Component Replacement

5

Replace Boots• Remove the brake assembly as described in the

“Remove Brake Assembly” section.

• Clean brake caliper of brake dust using clean shop rag. NEVER use mineral oil products.

• Using a rounded tip pick remove the big spiral rings (4) and the small spiral rings (5) then discard.

• Remove the piston boots (3) from the caliper housing and piston groove then discard.

• Inspect cylinder bores and pistons for contamination and corrosion. Replace pistons and seals as described on page 6 if needed.

• Slide new boots over the piston ends and cylinder grooves. Ensure the boot lips are seated well into the grooves.

• Install new small spiral rings (5) over the boot lip and piston groove without damaging the boots. Ensure the spiral rings are installed correctly and hold the boots on the pistons.

• Install the big spiral rings (4) over the boot lip and cylinder groove without damaging the boots. Ensure the spiral rings are installed correctly and hold the boots.

• Install the brake assembly as described on page 8.

Component Replacement

6

Replace Pistons and Seals• Remove the brake assembly as described on page 4.

• Remove piston boots as described on page 5.

• Using two large screw drivers or pry bars to remove the pistons one at a time.

• Clean the pistons using a clean, soft shop rag.

• Inspect the outside surface of the two pistons for scratches, nicks, scoring, corrosion, wear, and damage. Discard pistons and replace with new, if any of these conditions exist.

• NEVER refi nish the pistons with abrasive material as the outside diameter will become too small and out of round, resulting in actuation fl uid leaks.

• Remove piston seals from cylinder grooves using a rounded pick and discard. Do not scratch, nick, or scar the bores or the seal grooves.

Component Replacement

7

• Clean the caliper bores using a clean, lint-free shop rag.

• If necessary, clean above seal groove with a brass wheel and rotary tool or use Type-A Very Fine Scotch-Brite™.

• NEVER refi nish the seal grooves or the caliper bores under the seal grooves with abrasive material as the inside diameter will become too large and out of round, resulting in actuation fl uid leaks.

• Vacuum or blow compressed air then wipe off any fi bers or contaminants from the cylinder bore with a clean shop rag. Ensure no fi bers or other contaminants are left inside.

• Inspect caliper bores for scratches, nicks, scoring, corrosion, wear, and damage. Replace brake caliper, if any of these conditions exist.

• Coat caliper bores and the new seals with correct brake actuation fl uid.

• Install the new seals in the seal grooves.

• Clean the pistons and coat with correct brake actuation fl uid.

• Install one piston at a time, straight in the bore, with the groove facing out. Push the two pistons all the way in the cylinder bores.

• Install piston boots as described in “Replace Boots” on page 5.

! CAUTIONMAKE SURE THE PISTONS DO NOT TILT INSIDE THE CYLINDER BORES AND GET COCKED

• Install brake assembly as described on page 8.

Component Replacement

8

Install Brake Assembly• Inspect the piston boots (3) and spiral rings (4 & 5) to ensure they are installed correctly and the pistons (1) are fully

retracted in the bores.

• Clean the brake rotor surfaces and inspect as described on page 3.

• Slide the brake caliper (8) over the rotor and align the two mounting holes with the knuckle or brake adaptor plate holes.

• Use new mounting bolts and add medium strength liquid threadlocker on threads before installing.

• Install the shoulder bolt in the anchor side hole as shown in the illustration below.

• Install the standard bolt in the other mounting hole.

• Torque mounting bolts to 460 N·m (340 lbs. ft.).

• Connect the hydraulic line to the inlet port. Torque to 12-16 N·m (9-12 lbs. ft.) for DIN 74234 fl ange F “bubble” style connector or to 15-18 N·m (11-13 lbs. ft.) for banjo style connector with fl at washer seal.

• Install brake pads (12), pad retaining spring (11), pad retaining pin (9), and cotter (8) as described in “Replace Brake Pads” on page 4.

• Bleed the brake per the vehicle manufacturer.

Troubleshooting

9

Troubleshooting

Conditions Possible Causes Corrections

Caliper leaks at the bleeder

Bleeder screw under torqued Check torque on bleeder screw

Bleeder screw damaged Replace bleeder screw

Bottom of bleeder hole damaged in caliper housing

Replace caliper

Caliper leaks at the inlet port

Inlet fi tting not torqued properly Check torque on the inlet fi tting

Damaged fi tting, seal washer, or inlet port hole

Check fi tting, seal washer, or bottom of the inlet port hole for damage; replace as necessary

Caliper leaks at the pistons

Damaged or worn piston seals Replace piston seals

Damaged or worn pistons Replace pistons

Piston bore scored or corroded Replace brake assembly

Dragging brake Piston not retracting / frozen piston Replace brake assembly

Low brake torque / long pedal travel

Air in brakes or hydraulic system Bleed brakes

Brake fl uid level low Add brake fl uid to recommended level

Damaged or worn piston seals Replace piston seals

Contaminated or oil-soaked brake pads Replace brake pads

Incorrect pad lining material Replace brake pads

Brake vibration and noise

Backing plate against the rotor Inspect for brake pad and rotor damage;replace as necessary

Incorrectly installed brake pads Install brake pads correctly

Worn brake linings Replace brake pads

Excessive rotor runout Check rotor runout using a dial indicator; replace if out of spec

Rust or mud built up on edge of rotor or on brake caliper

Clean or replace as necessary

Service Kits

10

Service KitsItem Part Name Qty

Brake Pad Kit for 2 Brake Calipers - PN 940002908A01

12 Brake Pad 4

Pad Retainer Spring and Bar Kit - PN 940002908A02

9 Pads Retainer Bar 1

10 Cotter 1

11 Pads Retainer Spring 1

Bleeder Kit - PN 940002908A05

6 Bleeder Protector 2

7 Bleeder 2

Seal Kit for DOT Fluids - PN 940002908A04

2 Piston Seal 4

3 Piston Boot 4

4 Spiral Ring 4

5 Sprial Ring 4

Piston and Seal Kit for DOT Fluids - PN 940002908A03

1 Piston 60mm 4

2 Piston Seal 4

3 Piston Boot 4

4 Spiral Ring 4

5 Spiral Ring 4

Seal Kit for Mineral Oil Fluids - PN 940002908A07

2 Piston Seal 4

3 Piston Boot 4

4 Spiral Ring 4

5 Spiral Ring 4

Piston and Seal Kit for Mineral Oil Fluids - PN 940002908A06

1 Piston 60mm 4

2 Piston Seal 4

3 Piston Boot 4

4 Spiral Ring 4

5 Spiral Ring 4

© 2018 AxleTech International LLC. All rights reserved. AxleTech and AxleTech International are registered trademarks of AxleTech International LLC.All other brands and product names are trademarks or registered trademarks of their respective owners. Information supplied by AxleTech is believed to be accurate and reliable. AxleTech reserves the right, without notice, to makes changes in product design or specifications.

Customer Service 877-547-3907+33 (0) 4 77 92 88 92

Customer Service Fax877-547-3987

Email OE: sales@axletech.comAftermarket: aftermarket@axletech.com

www.axletech.com

BSM-0460E 03/19