Technical Bulletin 2014
Technical Bulletin 2014
Brake Discs & Drums Technical Document
Reference
Product
2 Inlet risk assessment - Ford, Land Rover, LDV
BE014
Brake Calipers
Audi rear caliper identification
BE015
Brake Calipers
CA2287 - Citroen C5 Oldcore return guide
BE016
Brake Calipers
Leading & Trailing caliper guide
BE017
Brake Calipers
Citroen C5 front caliper identification
BE018
Brake Calipers
Core acceptance guide
BE019
Brake Calipers
Handbrake caliper fitting procedure
BE021
Brake Calipers
Handbrake caliper reset procedure
BE022
Brake Calipers
LDV front caliper identification
BE023
Brake Calipers
Standard mechanical caliper check
BE010
Brake Calipers
Volvo S40/V40 real caliper identification
BE025
Brake Calipers
Brake disc wear guide
BE011
Brake Discs
Loose wheel retaining bolts
BE012
Brake Discs
disc with intergrated wheelhas bearing Brake BE037 the aftermarket Brake Discs throughout and this is For over 30 years Brake Engineering undoubtedly one of the key contributors produced precision-engineered brake Bedding the brake pads BE013 Brake Pads to the success, development and discs and drums using the very latest progression group today. in CNCFitting technology Kits with ever improving BE032 of this product Brake Pads The company’s market leading disc levels of unrivalled quality. Coupled with Concentric slave cylinder fitting instructions andBE028 drum catalogue Hydraulics is widely recognised an excellent worldwide sourcing strategy, as being number oneHydraulics for the aftermarket the company now offer a flexible range that Dangers of conductivity type brake fluid testers BE029 user with excellent range development not only has an enviable reputation as the Dot 4 material data sheet but BE026 as the main focus. Hydraulics major benchmark in safety the aftermarket A consistent new parts introduction also enables the product group to remain Ford Mondeo master cylinder warning BE027 Hydraulics programme ensures that the company competitive in the global marketplace. continue The Brake brake discs and BlockEngineering exemption regulator BE036 to achieve market General leader status striving towards 100% vehicle drums programme is noted as being parc coverage. the front-runner in range coverage
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Technical
Bulletin 2 inlet calipers - Risk assessment Vehicles: Ford Transit - Land Rover - LDV Calipers concerned:
CA14/R - CA327/R - CA394/R - CA462/R - CA752/R - CA1065/R - CA1219/R - CA1587/R
Warning: Do not block these inlets
The above calipers are all 2 inlet fitting and must NOT be fitted to 1 inlet applications. By blocking one of the inlets braking efficiency will be considerably reduced, as only two of the four pistons will be working.
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Technical Helpline: +44 (0) 1978 667811
TRW UK Aftermarket, Redwither Road, Wrexham Industrial Estate, Wrexham LL13 9RD
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Technical
Bulletin Audi Rear Caliper Identification - Audi A4 CA1498 / CA1498R Inlet: 10mm (Std) Piston: 38mm Disc: Solid Casting No: LH-6142 RH-6143 Inlet next to bleed screw
CA2441 / CA2441R Inlet: 12mm (Ban) Piston: 43mm Disc: Vented Casting No: LH-542 RH-543 Inlet opposite to bleed screw
CA1514 / CA1514R Inlet: 10mm (Std) Piston: 38mm Disc: Solid Casting No: LH-4061 RH-4062 Inlet 90 degrees to bleed screw
CA2447 / CA2447R Inlet: 12mm (Ban) Piston: 38mm Disc: Solid Casting No: LH-737 RH-738 Inlet next to bleed screw
CA1987 / CA1987R Inlet: 12mm (Ban) Piston: 38mm Disc: Solid Casting No: LH-877 RH-878 Inlet opposite to bleed screw
CA2583 / CA2583R Inlet: 10mm (Std) Piston: 43mm Disc: Vented Casting No: LH-542 RH-543 Inlet opposite to bleed screw
Std = Standard inlet pipe fitting Ban = Banjo inlet pipe fitting www.brake-eng.com
Page 1 of 3
Technical Helpline: +44 (0) 1978 667811
TRW UK Aftermarket, Redwither Road, Wrexham Industrial Estate, Wrexham LL13 9RD
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Technical
Bulletin Audi Rear Caliper Identification - Audi A6 CA1195 / CA1195R Inlet: 10mm (Std) Piston: 38mm Disc: Solid Casting No: LH-2624 RH-2625 Inlet next to bleed screw
CA1237 / CA1237R Inlet: 10mm (Std) Piston: 43mm Disc: Vented Casting No: LH-32322392 RH-32322393 Inlet next to bleed screw
CA2026 / CA2026R Inlet: 12mm (Ban) Piston: 38mm Disc: Solid Casting No: LH-046 RH-047 Inlet opposite to bleed screw
CA2441 / CA2441R Inlet: 12mm (Ban) Piston: 43mm Disc: Vented Casting No: LH-542 RH-543 Inlet opposite to bleed screw
CA1474 / CA1474R Inlet: 10mm (Std) Piston: 38mm Disc: Solid Casting No: LH-4060 RH-4061 Inlet opposite to bleed screw Std = Standard inlet pipe fitting Ban = Banjo inlet pipe fitting www.brake-eng.com
Page 2 of 3
Technical Helpline: +44 (0) 1978 667811
TRW UK Aftermarket, Redwither Road, Wrexham Industrial Estate, Wrexham LL13 9RD
http://www.brake-eng.com/Tech-Talk/
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Technical
Bulletin Audi Rear Caliper Identification - Audi A8 CA1195 / CA1195R Inlet: 10mm (Std) Piston: 38mm Disc: Solid Casting No: LH-2624 RH-2625 Inlet next to bleed screw
CA2328 / CA2328R Inlet: 12mm (Ban) Piston: 43mm Disc: Vented Casting No: LH-559 RH-560 Inlet next to bleed screw
CA1510 / CA1510R Inlet: 10mm (Std) Piston: 43mm Disc: Vented Casting No: LH-4921 RH-4922 Inlet next to bleed screw
CA2315 / CA2315R Inlet: 10mm (Std) Piston: 38mm Disc: Solid Casting No: N/A Inlet opposite to bleed screw Std = Standard inlet pipe fitting Ban = Banjo inlet pipe fitting www.brake-eng.com
Page 3 of 3
Technical Helpline: +44 (0) 1978 667811
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Technical
Bulletin Citroen C5 Oldcore Return Guide
Beware of damaged pad pin holes when returning CA2287 & CA2287R, all old units returned like this will be rejected for surcharge credit
CA2287 & CA2287R Piston Diameter: 32 mm Pad Gap: 49.5 mm Casting Numbers: 9629086010
!
Beware of broken pad pin holes
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Technical Helpline: +44 (0) 1978 667811
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Technical
Bulletin Leading & Trailing Calipers
Brake
Trailing Caliper
Leading Caliper
The caliper is mounted on the rear of the disc
The caliper is mounted on the front of the disc
Please note: On some applications it is possible to have eiither a leading ot trailing caliper positions using the same caliper For example: Caliper N/S Caliper O/S Make Model
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Year
Axle
MAN
LD/TR
CA1243
CA1243R
Ford
Mondeo
03/93>10/00
F
ATE
LD
CA1243R
CA1243
Ford
Scorpio
01/95>07/98
F
ATE
TR
Technical Helpline: +44 (0) 1978 667811
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Technical
Bulletin Citroen C5 Front Calipers There are 2 options of front calipers for 2.0 & 2.2 HDi
CA2115 & CA2115R Disc Diameter: 283 mm Disc Thickness: 26 mm Casting Numbers: 1083 (LH) 1084 (RH) Mounting Holes (Centre to Centre): 175 mm
CA2116 & CA2116R Disc Diameter: 288 mm Disc Thickness: 28 mm Casting Numbers: 1086 (LH) 1087 (RH) Mounting Holes (Centre to Centre): 188 mm
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Technical Helpline: +44 (0) 1978 667811
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At Brake Engineering we have strict guidelines when it comes to core returns. Please follow these acceptance criteria when returning old core. Core will not be eligible for refund if it has any of these faults.
Caliper Core Acceptance Criteria Bleed Screw
Bracket Arm
Bleed Screw should not be excessively damaged
x
Bracket arm should not be damaged
P
Brake Disc
Carrier guide should not be damaged
P
Entry Port
P
Handbrake cable guide should not be damaged
P
Mounting Feet
x
P
Pad Pin Holes
Mounting feet should not be damaged
x
x
Handbrake Cable
Entry port should not be snapped or damaged
x
P
Carrier Guide
Casting should not be worn due to brake disc
x
x
Pad pin holes should not be broken
P
x
P
Corroded End Faces
Aluminium split calipers end faces should not be corroded
x
P TRW UK Aftermarket Redwither Road, Wrexham Ind Estate, Wrexham LL13 9RD Technical Helpline: +44 (0)1978 667811 www.brake-eng.com/Tech-Talk/
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Technical
Bulletin Hand Brake Caliper Fitting Procedure
DO NOT operate handbrake lever before fitting to the vehicle. The unit has been preset at the factory, if you have to, go to the last paragraph. Adjust the pad gap on the brake caliper using the adjusting procedures below to ensure there is no more than 1mm clearance between both brake pads and disc. ADJUSTING PAD GAP BRAKE CALIPER TYPE A (LUCAS, AKEBONO, BENDIX) Using an Allen key or pair of long nose pliers in the dedicated slots on the front of the piston. Rotate piston anti-clockwise to move the piston ‘out’. If the piston is rotated in it must be rotated at least half a turn out to ensure the internal mechanism has reset before you proceed any further. Fit the brake caliper and brake pads but do not fit the handbrake cable. Fully bleed the hydraulic system. Fit the handbrake cable and adjust to remove any slack. Make sure that the gap between the lever-to-stop does not exceed 1mm. ADJUSTING PAD GAP BRAKE CALIPER TYPE B (ATE & NBK) Remove plug on rear caliper. Using 4mm Allen key adjust piston, do not use excessive force as this can cause damage. Rotate Allen key clockwise to move the piston ‘out’. If the piston is wound in at any stage it must be wound out again by at least half a turn of the adjuster to ensure the internal mechanism has reset before you proceed any further. Fit the brake caliper and brake pads but do not fit the handbrake cable. Fully bleed the hydraulic system. Fit the handbrake cable and adjust to remove any slack. Make sure that the gap between the lever-to-stop does not exceed 1mm. To reset the handbrake mechanism if the lever has been operated before fitting then the piston should be turned ‘in’ using the above methods. When the piston is fully ‘IN’ then the piston should be turned ‘OUT’ half to 1 turn. The handbrake mechanism is now set. CAUTION: DO NOT OVER ADJUST CALIPER OR SPLINES WILL STRIP ON ADJUSTER www.brake-eng.com
Technical Helpline: +44 (0) 1978 667811
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Technical
Bulletin Hand Brake Caliper Reset Procedure If the hand brake lever is moved prior to fitting and adjustment to the vehicle. It will throw the automatic hand brake adjustment out. If this happens, the hand brake mechanism will have to be reset by the following methods. FOR TYPE A CALIPERS (SLOTS IN PISTON TYPE) If the caliper has not been fitted to the vehicle. Using a suitable tool, locate the slots in the piston and turn it in clockwise (Take care! later calipers can have a left hand thread) Until it stops. Turn the piston back out between ¼ and ½ turn. This resets the mechanism back to the lever. Continue to turn the piston out until you reach the neccessary adjustment of 1 mm clearance between the disc and the pads. If there is alocating peg on the back of the pads, you will need to line this peg up with a slot in the piston. The easiest way is to mount the pads in the caliper and then slide the whole assembly over the disc. Bleed the caliper through, then operate the pedal a few times to centralise the assembly. Finally connect the hand brake cable and adjust accordingly. If the caliper has been fitted to the vehicle and the adjustment has been lost. You will need to start the reset procedure by first taking off the hand brake cable, then clamping off the hydraulic flexi pipe, then open up the bleed screw. Then follow the above procedure. FOR TYPE B CALIPERS (THREADED PLUG ON BACK OF CALIPER) Remove the threaded plug to reveal an allen headed bolt type adjuster. Using a 4 mm allen key, turn it anti-clockwise to wind the piston in until it stops. Turn the allen key clockwise to wind the piston back out between ¼ and ½ turn. Then follow the above instructions for (Type A) caliper, but using the allen key to turn the piston. DON’T FORGET TO REPLACE THE THREADED PLUG.
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Technical Helpline: +44 (0) 1978 667811
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Technical
Bulletin LDV Front Caliper Identification CA462 / CA462R
CA937 / CA937R
Discs: Solid Inlet: Twin Pad Pin Holes: 5mm
Discs: Solid Inlet: Single Pad Pin Holes: 7mm
CA778 / CA778R
CA1065 / CA1065R
Discs: Vented Inlet: Single Pad Pin Holes: 5mm
Discs: Vented Inlet: Twin Pad Pin Holes: 5mm
CA846 / CA846R
CA1216 / CA1216R
Discs: Solid Inlet: Single Pad Pin Holes: 5mm
Discs: Vented Inlet: Single Pad Pin Holes: 7mm
Once these criteria have been matched, we then need to know whether the calipers are leading or trailing on the vehicle.
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Technical Helpline: +44 (0) 1978 667811
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http://www.brake-eng.com/Tech-Talk/
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What is a standard mechanical Caliper check? The standard check of a Caliper should consist of the mechanical function check of all the Caliper parts. As a second part this test should include the visual inspection (leaking, cracking and wear of the parts) Sticking Brake Pads as a example (see picture) are often the reason for noise occurrence, judder and / or overheated Brakes. Guide Pins have to move smoothly. Wheel hubs and centre rings of Disc should be free of corrosion and without damage otherwise judder could occur Handbrake cable moves free
Guide Pins
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Technical Helpline: +44 (0) 1978 667811
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Technical
Bulletin Volvo S40 / V40 Rear Caliper Identification There are 2 options of rear calipers for the Volvo S40/V40, these calipers are not interchangeable. CA1746 / CA1746R
Without external hand brake return spring
CA1746 / CA1746R
With external hand brake return spring
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Technical Helpline: +44 (0) 1978 667811
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Technical
Bulletin
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Brake Disc Wear Blue coloured brake disc The cause of the blue colour is continuous braking during driving downhill or hard braking from a high speed. The blue colour has no direct impact to the brake efficiency. If there are cracks or deformations, change as an axle set.
Cracked disc Continuous braking during downhill driving or hard braking from a high speed causes extreme temperature differences. This could lead to cracks. Brake discs have to be changed as an axle set.
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Technical
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Brake Disc Wear Ridged disc The surface of the disc should be smooth Slight grooves are acceptable A heavily scored disc must be replaced
Corroded disc Any corrosion of a brake disc might be for the following reasons: • • • •
Malfunction of hydraulic parts LCRV / PCRV problem Soft use of braking system Low car mileage
Page 2 of 2
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Technical Helpline: +44 (0) 1978 667811
“Tech-Talk“
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Loose Wheel Retaining Bolts The reason identified for this problem is corrosion between the disc and hub mounting faces. Step 1:
Step 2:
Remove the brake disc
Scrub hub face with a wire brush, removing all corroded material Corroded Material
Step 3:
Step 4:
Sand down the hub face, removing any remaining corrosion
Measure the contact area of hub and wheel The hub could be out of shape by using an impact wrench. Check the hub with a ruler.
Step 5: www.brake-eng.com
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Re-install retaining bolts and replace disc onto the clean hub,
Technical Helpline: +44 (0) 1978 667811
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Technical
Bulletin Brake disc with integrated wheel bearing Never compromise on safety Our bearing discs with integrated bearing are manufactured to the highest standards. Never compromise on safety, fit Brake Engineering. Advantages: • • • • • •
Complete kit, including all the necessary replacement parts for mounting brake disc with integrated wheel bearing, washer, ASB®-magnetic encoder (Active Sensor Bearing) nut and cover. Simple, quick and precise mounting. No special tools necessary to press the wheel bearing. Avoids wrong mounting. Assembling loose components to one unit often causes problems with the fitting, aligning and the clearance. Perfect fitting to avoid complaints about vibrations and noise, caused by the brakes. 100% identical to the original product. Therefore, it meets the high demands of the car manufacturers.
Beware of imitations! There are also some copies on the market which can be dangerous for the safety of the driver. Intensive tests have been performed and here are the main findings: • •
The integrated bearings do not follow the OE-specifications, in particular for what concerns their lifespan and quality. Reduced lifespan can lead to premature failure of the brake and even loss of the wheel! The magnetic encoder (the patented ASB®-sensor ring) doesn’t have the necessary OEquality. Some of them do not even have the same number of poles! This causes almost every time a malfunction in the ABS-and ESP-system.
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Damaged Magnetic Pole www.brake-eng.com
Normal Magnetic Pole
Page 1 of 5
Technical Helpline: +44 (0) 1978 667811
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Technical
Bulletin Brake disc with integrated wheel bearing Why risk your safety? A premium product is not only the guarantee of quality and durability, it is also the best way to ensure safety reliability of your vehicle. You wouldn’t make any economies with your life. So why risk you life by buying counterfeit products? Mounting Tips Brake discs are safety parts. Install the part carefully and always work in a clean working place. Although mounting a brake disc with integrated bearing is simple, a few points you have to pay attention to. 1. The nut and cover always have to be replaced. If the old nut and cover are used, the risk exists that these can get loose again. 2. Clean the axle journal. 3. Clean the ASB®-sensor and check with the ASB®-test card. 4. Install the brake disc with integrated bearing without force on the axle journal (loose fit) and don’t forget to degrease. 5. Make sure that the disc doesn’t tilt. The inner ring can easily be pushed. Tools are not necessary and should not be used. 6. Place the washer (if present) in the right position and turn the new nut to the stop with the hand. The brake disc has to be turned continuously in the meantime to guarantee an exact centering of the bearing components. An impact drive should not be used. 7. Pull the axle nut to the correct torque. Take into account the torque specifications of the car manufacturer. The torque should be exact. The vehicle should not stand on the wheels and also here, the brake disc has to be turned continuously in the meantime. 8. Don’t expose the wheel bearing to magnetic fields. Otherwise, the ASB®-sensor ring may be damaged. 9. Grease the contact surface of the nut cap before mounting. Use a wooden hammer to avoid deformation.
Page 2 of 5
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Technical
Bulletin Brake disc with integrated wheel bearing Remarks The ASB ®-Magnetic encoder ring is not sold separately in the aftermarket because this ring cannot be removed or replaced without damaging. Using a screwdriver as a “removal tool”, only a small part of the ring can be lifted. This can result in a deformation of the ring. Using a hammer to mount the magnetic ring can cause visible and invisible damage. A system failure can appear quickly as soon as the magnetic ring is mounted on the new brake disc. This can lead to a failure in the ABS-system and the consequences can be fatal.
The European Law forbids the mounting and use of brake discs with uneven wear on the same axle. Therefore, both brake discs should be replaced at the same time.
Page 3 of 5
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Technical Helpline: +44 (0) 1978 667811
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Technical
Bulletin Brake disc with integrated wheel bearing The advantages of an ASB®-bearing The ASB®-bearing measures the rotation and speed of the wheel and sends the data to the considered systems in the vehicle. The active sensor sends a digital signal to the vehicle computer and has many advantages, among which: • • • •
The possibility of measuring wheel speed down to zero. Saving in space and weight. Simplified assembly of wheel. Standardisation of the components.
Page 4 of 5
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Technical
Bulletin Brake disc with integrated wheel bearing Part No
Make
Model
Start Year
End Axle Bearing/ Year ABS Info
OE Numbers
DI956714S
CITROEN / PEUGEOT
C3 / C3 PICASSO
2001
2009
R
+Bearing +ABS
424919, 424932
DI956396S
CITROEN / PEUGEOT
C4 / 307
2003
2006
R
+Bearing -ABS
4246Z9
DI956700S
CITROEN / PEUGEOT
C4 / 307
2001
2006
R
+Bearing -ABS
4246Z9, 424934
DI956856S
CITROEN / PEUGEOT
C4 / 308
2007
R
+Bearing +ABS
424965, 424966
DI956618S
NISSAN / RENAULT / VAUXHALL
PRIMASTAR / TRAFIC / VIVARO
2001
2008
R
+Bearing +ABS
7711130076
DI956936S
RENAULT
CLIO
1991
1997
R
+Bearing +ABS
7701207611
DI956425S
RENAULT
CLIO / GRAND MODUS / MEGANE / MODUS / TWINGO / WIND
2002
2011
R
+Bearing -ABS
7701207823
DI956648S
RENAULT
CLIO / GRAND MODUS / MEGANE / MODUS / TWINGO / WIND
2002
2012
R
+Bearing +ABS
8867108106
DI956937S
RENAULT
CLIO / MEGANE
1996
2005
DI956940S
RENAULT
ESPACE / GRAND ESPACE / VEL SATIS
2002
DI956672S
RENAULT
ESPACE / GRANDE ESPACE / VEL SATIS
2002
DI956532S
RENAULT
GRAND SCENIC / MEGANE / SCENIC
2003
DI956971S
RENAULT
GRAND SCENIC / SCENIC
2009
DI956713S
RENAULT
GRAND SCENIC / SCENIC (LWB)
2003
R
+Bearing +ABS
7701204901
R
+Bearing +ABS
8200018407, 7701206924, 8200663193
2006
R
+Bearing +ABS
8200244108
2009
R
+Bearing +ABS
7701207898
R
+Bearing +ABS
432000007R
2009
R
+Bearing +ABS
7701208230
DI956924S
RENAULT
KANGOO
2008
R
+Bearing +ABS
8200381148
DI956264S
RENAULT
LAGUNA
1998
2008
R
+Bearing +ABS
7701472838, 7701713008, 8200367094
DI956402S
RENAULT
LAGUNA
2001
2008
R
+Bearing -ABS
7701713008, 7701472838, 8200367094
DI956728
RENAULT
LAGUNA
2008
2012
R
+Bearing +ABS
402020005R
DI956923S
RENAULT
LAGUNA
2007
R
+Bearing +ABS
402020003R
DI956889
RENAULT
MEGANE
2008
R
+Bearing +ABS
432001539R
DI956906S
RENAULT
MEGANE
2005
DI956979
RENAULT
MEGANE
2005
DI956136S
RENAULT
MEGANE / SCENIC
1997
2009 2003
R
+Bearing +ABS
7701208850
R
+Bearing +ABS
8200266043
R
+Bearing +ABS
7701206328
Page 5 of 5
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Technical Helpline: +44 (0) 1978 667811
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Bedding the Brake Pads Brake Pad
Brake Disc
Brake Pad
New brake pads must be bedded. The surface area of the disc and pad must be even for optimal braking performance, this is why it is important during the bedding in process to avoid heavy braking, to allow the pad and disc surface to even-up with each other. Disc Surface
Bring the brake pads in their operating position by pressing the brake pedal down (half of normal pedal travel) several times until there is resistance. Check the brake fluid level, and top up to ‘Max’ mark if necessary. Note: In order to bed the brake pads to the brake disc and ensure performance and endurance, the vehicle user must be instructed to avoid heavy braking or sustained periods with the brakes applied, for the first 200 miles after installing new pads.
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0 Miles
200 Miles
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Bulletin Fitting Kits Although the Brake Engineering Pad and Shoe range comes complete with safety critical brake accessories (i.e. caliper bolts, handbrake lever circlips/washers etc) supplementary brake fitting kits are not included. Brake Fitting Kits - The Mechanics Friend How many times is a Pad or Shoe reline delayed, or additional costs incurred, when essential brake accessory clips and/or springs are found to be worn, damaged or missing ? The Brake Engineering catalogue contains information on a comprehensive range of brake accessory fitting kits now available. Brake Fitting Kits - Easier referencing Where a brake fitting kit is required this is listed in the application section, alongside the appropriate Pad or Shoe part number. All Brake Engineering fitting kit part numbers are ‘pre-fixed’ by the letter ‘QK’ Brake Engineering also has available ‘Point-of-Sale’ Brake Accessory Display Stands, complete with the popular kits. Please ask you Area Manager for further details. Part Number Range QK0501-0767 are Fitting Kits for Drum Brake/Shoe applications QK0901-1273 are Fitting Kits for Disc Brake/Pad applications All kit packaging contains cross-reference information as to which Pad or Shoe part number they should befitted with. This information is also shown on the Pad and Shoe packaging. Fitting Kit Contents Drum Brake Kits include: Shoe ‘hold-down’ accessories and return springs Disc Brake Kits include: Pad anti-rattle springs and caliper pad retention pins.
The importance of specifying Fitting Kits when replacing pads and show... Pad Fitting Kits Correct fitment of pad retention pins enables the Pads to move freely within the caliper housing during operation. Worn, damaged, or badly corroded parts will cause in a brake imbalance and and/or seizure of brake components, particularly between the ‘inboard’ and ‘out-board’ Pads, resulting in uneven wear, reduced brake efficiency, brake pull and judder! Correct fitment of anti-rattle springs hold the pads correctly in place within the caliper housing, preventing vibration, the prime cause of brake noise/squeal! Shoe Fitting Kits Correct fitment of shoe ‘hold-down steady posts and springs’ ensures that the brake shoes remain parallel with the brake drum surfaces at all times Worn, damaged, weak or badly corroded parts will prolong bedding, increase the risk of uneven lateral taper wear and wheel lock! The fitment of new shoe return springs ensures that a correct running clearance is maintained when the brakes are released. Worn, damaged or weak springs may result in the brakes ‘hanging-on’. This will result in excessive temperature operation, rapid wear and possible wheel lock conditions! www.brake-eng.com
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Bulletin 97 86 Concentric Slave Cylinder 67 81 Concentric Cylinder SERVICE Slave INFORMATION 1 Fitting Instructions rev. 07/2010 01/2010 01
Fitting Instructions
Page 1 of 4 Fitting instructions for the Concentric Slave Cylinder (CSC) The concentric slave cylinder (CSC) is subjected to just as much natural wear as the clutch or flywheel and should be replaced every time the clutch is changed. There are a few important things to consider during installation in order to preserve the functionality and service life of the components.
!
!
Always read the specifications of the vehicle manufacturer
Critical points when fitting the CSC: • • • • • • • • • • • • • •
Do not repeatedly pump the clutch pedal when bleeding; depress just once and wait for hydraulic system to stabilize before pumping again. (Risk of over pressure inside CSC) Do not use any lubricants or cleaning agents as they may damage the gaskets or entire cylinder. A high level of cleanliness is critical at all times. Only use brake fluid approved by the car manufacturer. Gaskets, seals and the connection areas must be totally clean. Clean the transmission input shaft and ensure that there is no damage or excessive wear on shaft seal area. Make sure the slave cylinder is installed flat against the transmission-mounting surface Fit the slave cylinder cy fixing g bolts and tighten g per p the vehicle manufacturer requirements. q Flush the connecting hose through with clean fluid before assembly to prevent contamination of the new cylinder. Fill the reservoir with an approved DOT 3 or 4 brake fluid. NEVER bleed the CSC if the clutch and flywheel are not yet assembled. Make sure the CSC is not tilted during installation. Failure may lead to damage of the fixing lugs or reduced service life. Do not over tighten bleed screw. Bleed screw torque for Plastic housing (3 to 5 Nm) - for Aluminum housing (15 to 20 Nm)
THE ENTIRE CLUTCH MECHANISM SHOULD BE CHANGED WHEN FITTING A NEW CONCENTRIC SLAVE CYLINDER, Dispose of the waste oil and used parts according to proper country and/or state disposal regulations
!
DAMAGE CAUSED BY INCORRECT OR POOR FITTING PRACTISE WILL NOT BE HONOURED UNDER WARRANTY.
!
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CSC001
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SubjectTechnical to technical changes Support PAGE 1Brake of 4 Engineering ©2010 LPR s.r.l.
lpr.info@lpr.it TRW UK Aftermarket, Redwither Road, Wrexham Industrial Estate, Wrexham LL13 9RD
S-info_01/2010 – rev. 07/2010
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Bulletin Concentric Slave Cylinder Concentric Slave Cylinder SERVICE INFORMATION Fitting Instructions Fitting Instructions 01/2010 01
97
86 67 81 1
rev. 07/2010
ASSEMBLY ERRORS 1 - FRICTION PLATE WRONG WAY AROUND
ASSY
If the friction plate is assembled the wrong way around, it will damage the retaining ring and cause leakage.
Page 2 of 4
Retaining ring damage
ASSY
2 - OVER STROKE
Repeated pumping of the clutch during bleeding can cause the clutch slave to over stroke. stroke This will result in the damage of the retaining ring or primary seal as the sliding sleeve can slip out of the bore. The main seal will also be damaged if it attempts are made to re-fit it. Over-stroke retaining ring damage
CSC001 www.brake-eng.com
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Typical Over-stroke seal damage
Subject to technical changes Brake Technical Support PAGE 2 of 6 Engineering ©2010 LPR s.r.l. S-info_01/2010 – rev. 07/2010
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Bulletin Concentric Slave Cylinder Concentric Slave Cylinder SERVICE INFORMATION Instructions FittingFitting Instructions 01/2010 01
97
86
67
81
1
rev. 07/2010
Page 3 of 4
3 - AXIAL AND ANGULAR SHAFT/ENGINE MISALIGNMENT The transmission shaft must be perfectly aligned during fitment, as excessive axial or angular misalignment will stress the primary seal causing a reduction in the life of the unit. Possible causes of misalignment are: • Centering between engine and gear box is not correct (deformation, heavy dirt or wear); • Other parts (e.g. grounding straps) trapped between engine and gear box during installation); • Flange bolts loose or not properly tightened; • Close-tolerance sleeves or pins missing / 1: parallel offset ; 2: Angular offset damaged; • Pilot bearing in the flywheel is absent or badly worn; • Clutch bell housing warped due to unevenly or over torqued fixing bolts • Clutch bell housing deformed due to dropping or striking hard when fitting. If there is excessive axial or angular misalignment, when the transmission shaft rotates it can generate mineral oil mist which can contaminate the primary seal leading to failure of the cylinder.
4 – INCORRECT FLUID USE The clutch hydraulic system MUST only be filled with the manufacturers recommended fluid. Never use mineral oil. oil
!
If the wrong hydraulic fluid is used, the seals in the system will be damaged.
Volume change - contact with mineral fluid STD dimension
In systems which are combined with the brake system, seals in the brake system may arise.
POTENTIAL FOR ACCIDENTS!
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seal after contact with mineral oil
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Bulletin Concentric Slave Cylinder Concentric Slave Cylinder SERVICE INFORMATION Fitting Instructions Fitting Instructions 01/2010 01
97
86
67
81
1
rev. 07/2010
Page 4 of 4
5 - BLEEDING ERROR – OVER PRESSURE DO NOT USE POWER ASSISTED BLEEDING DEVICES ON THE CLUTCH SYSTEM Use of these systems can over pressurize the concentric slave cylinder. If this occurs, it will cause permanent damage to the cylinder and it will need to be replaced! Manual bleeding should be carried out using the following process: 1. Depress clutch pedal 2. Open bleed valve 3. Keep clutch pedal depressed until fluid appears – Do not release! 4. Close bleed valve 5. Release clutch pedal slowly 6. Do not repeatedly pump the clutch The clutch bleeding cycle must be repeated 20 to 25 times to guarantee complete bleeding. Top up the level of the fluid in the reservoir between the cycles. The level of the fluid must not drop below the minimum mark on the reservoir during bleeding!
6 - CONTAMINATION – GEAR SHAFT Ensure that all contamination is removed during the disassembly and re-assembly processes. Any debris or swarf can contaminate the main seal and cause leakage..
Aluminum swarf causing leakage from gear side
!
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Bulletin Dangers of Conductivity Dangers of conductivity Type Brake Fluid Testers type brake fluid testers 01
97
86
67
81
1
Electronic devices to test automotive brake fluid when in service are becoming increasingly popular. Correctly designed and used, they can make a real contribution to road safety, while providing profit opportunities for garages. However, customers should be aware that these testers are not all of the same design and some are very much better than others. We are aware of many incidents where electronic brake fluid testers have incorrectly failed new product straight out of a bottle, while under different circumstances passing product as acceptable which had become dangerous for use. In our experience any brake fluid tester which does not actually heat the fluid is likely to give misleading or even dangerous results. Such testers will estimate the water content electronically by measuring the conductivity (or occasionally the capacitance) of the fluid, which in theory increases as water is absorbed. The tester then converts this measurement to supposed boiling point and indicates the result commonly as a display of green, yellow or red lights, depending on the conductivity. Unfortunately, this measurement principle is fatally flawed as the conductivity of new brake fluids varies substantially, from not only between DOT 3, DOT 4 or DOT 5.1 types but also from formulation to formulations within a DOT grade depending on the additives used. This means that unless a conductivity tester is calibrated on one manufacturer’s product and then used for that product only, it is likely to give very inaccurate results. Example of a In contrast to this type of equipment testers are available which conductivity type actually heat a sample of the fluid to establish the boiling point, Brake Fluid Tester thereby getting away from the problem of varying conductivities. In our experience these provide the best balance of performance and economy currently available. Even so caution is needed, careful handling and regular calibration being required if results are to be reliable.
In cases where customers require totally accurate water contents or boiling points, it is recommended that they return samples to Brake Engineering so that laboratory tests can be conducted to ensure that the fluid meets the required standards using industry standard techniques such as the well known Karl Fischer method for water content.
For further information please contact our Technical Department on (01978) 667811 www.brake-eng.com
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HYD001
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Bulletin Dot 4 Brake Fluid Material Safety Data Sheet 1. IDENTIFICATION 1.1 Product Name Brake Engineering DOT 4 Brake Fluid 2. COMPOSITION/INFORMATION ON INGREDIENTS 2.1 General Blend of polyglycol ethers, glycol ether borate esters and polyglycols with added corrosion and oxidation inhibitors. Hazardous Ingredients Einecs / Eilincs No.
CAS-Number
Concentration in %
Hazard Classification
Risk Phrases
Butyl tri glycol
205-592-6
143-22-6
>20
Xi
R36
Di ethylene glycol
203-872-2
111-46-6
<25
Xn
R22
Methyl di glycol
203-906-6
111-77-3
<5
Xn
R63
3. HAZARDS IDENTIFICATION 3.1 Physical Hazards Not significant. 3.2 Health Hazards R 36: Irritating to eyes. Mildly irritating to skin. When ingested it may be absorbed and cause renal damage at high dosage. 3.3 Environmental Hazards : Low 4.FIRST AID MEASURES 4.1 Inhalation - Remove to fresh air. If recovery is not rapid, seek medical attention. 4.2 Skin Contact - Remove contaminated clothing. Wash affected skin with soap and water.If irritation persists seek medical attention. 4.3 Eye Contact - Flush eye with water for at least 10 mins. If irritation persists seek medical attention. 4.4 Ingestion - Obtain medical advice immediately.If patient is fully conscious,wash out mouth with water and give plenty of water to drink.Induce vomiting only under medical supervision. 4.5 Note to Physicians - Medical personnel seeking to administer first aid are referred to the services of the Poisons Information Centre,who can advise in such instances. There is no specific antidote and treatment of over exposure should be directed at control of symptoms and the patientâ&#x20AC;&#x2122;s clinical condition. 5.FIRE FIGHTING MEASURES 5.1 Suitable Extinguishing Media Alcohol resistant foam,dry powder or water (fog or fine spray). 5.2 Unsuitable Extinguishing Media Water jets (although these may be used to cool adjacent containers). 5.3 Exposure Hazards No special risk â&#x20AC;&#x201C; combustion products may contain harmful or irritant fumes. 5.4 Special Protective Equipment In extreme conditions self-contained breathing apparatus should be worn. 6. ACCIDENTAL RELEASE MEASURES 6.1 Personal Precautions Avoid contact with eyes, skin, and clothing. When cleaning up large spillages, suitable protective clothing should be worn including eye protection and impervious gloves.
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Bulletin Dot 4 Brake Fluid Material Safety Data Sheet 6.2 Environmental Precaution Prevent from entering drains, ditches or rivers. If this happens inform relevant authorities. Prevent gross contamination of soil. 6.3 Methods for Cleaning Up Contain spillage using sand or earth. Remove all material to a suitable container for subsequent disposal. Label Salvage Container appropriately. Flush contaminated area with plenty of water. 7. HANDLING AND STORAGE 7.1 Storage Suitable bulk storage vessels are mild/stainless steel tanks fitted with a dry air breathing system or tight head steel drums. Do not store in lined tanks or drums. Brake fluid absorbs water from the atmosphere - always keep containers tightly closed. Avoid contamination with any other substances and in particular with mineral oils which are incompatible. 7.2 Handling No specific handling precautions are necessary. 7.3 Specific Use Users are referred to the Specification SAE J1707 â&#x20AC;&#x153;Service Maintenance of Brake Fluidsâ&#x20AC;? 8. EXPOSURE CONTROLS/PERSONAL PROTECTION 8.1 Exposure Controls No official TLV/OEL figures available for the entire preparation. However,8 h TWA limits of 100 mg/m3 vapour or 10 mg/m3 particulate should be adhered to and this will ensure no limits for ingredients are exceeded. Due to the low vapour pressure of the preparation,vapour is not generally a problem at ambient temperature. Handling equipment should minimise the formation of mists. 8.2 Respiratory Protection No specific precautions at ambient temperature. If fluid is being heated or atomised, use suitable engineering control measures. 8.3 Hand Protection Wear suitable impervious gloves to avoid prolonged or repeated contact. Polyethylene natural or butyl rubber and PVC are suitable materials. 8.4 Eye Protection Wear close-fitting goggles where there is a risk of splashing. Eye baths should be provided at locations where accidental exposure may occur. 8.5 Skin Protection Where significant exposure is possible wear impervious body covering.It is recommended that showers are provided at locations where accidental exposure may occur. 8.6 Environmental Exposure Controls No special measures required.
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Bulletin Dot 4 Brake Fluid Material Safety Data Sheet 9. PHYSICAL AND CHEMICAL PROPERTIES Physical
Chemical Properties
Tested in accordance with
9.1 - Appearance
Clear liquid - Usually colourless to amber although some grades of brake fluid may be highly dyed.
9.2 - Odour
Bland
9.3 - pH
7.0 to 10.50
SAE J 1703
9.4 - Boiling point
>205 Deg.C.
SAE J 1703
9.5 - Melting point
<-50 Deg.C.
SAE J 1703
9.6 - Flash point
>80 Deg.C. DOT 3, 90 Deg.C. DOT 4
IP 35
9.7 - Auto ignition temp.
>300 Deg.C.
ASTM D 286
9.8 - Flammability limits in the air
Not established
9.9 - Density @ 20°C
1.010 - 1.070 g/ml
9.10 - Solubility
In water: miscible in any ratio In ethanol: miscible in any ratio
9.11 - Partition Coefficient n-Octanol/ Water (log POW)
<2.0 (all main ingredients)
OECD 117
9.12 - Viscosity @ 20°C
Approx. 5-10 cSt
ASTM D 445
9.13 - Vapour pressure 20°C
< 2 milibars
Reid
9.14 - Vapour Density
Not established
9.15 - Evaporation Rate
Negligible
10. STABILITY AND REACTIVITY 10.1 Conditions to Avoid Product is stable under normal conditions.Glycol Ethers can form peroxide on storage – do not distil to dryness. 10.2 Materials to Avoid Strong oxidising agents. For user safety, brake fluid should never be contaminated with any other substance. 10.3 Hazardous Decomposition Products None known.
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Bulletin Dot 4 Brake Fluid Material Safety Data Sheet 11. TOXICOLOGICAL INFORMATION (comments may be based on analogy with similar products). 11.1 Eye Contact Product has an irritating effect on the eye. (Test Method OECD 405). 11.2 Skin Contact Not classified as irritant (Test Method OECD 404) although some sensitive individuals may be affected.Repeated contact may de-fat the skin and cause dermatitis. Product does not contain any known sensitisers. Acute percutaneous toxicity is low LD50 (sk) Rat = > 2000 mg/kg. 11.3 Ingestion Product is of relatively low acute oral toxicity – however,if any significant amount is ingested there is a risk of renal damage which in extreme cases could lead to kidney failure,coma and death. LD50 (oral) Rat = > 5000 mg/kg. Sparse experience indicates lethal dose in man could be considerably less. 11.4 Inhalation Unlikely to be hazardous by inhalation at ambient due to low vapour pressure.If product is inhaled at elevated temperatures or as an aerosol it may irritate respiratory tract and may cause systemic effects similar to ingestion (see above). 11.5 Chronic or Long Term Toxicity General – There are no reports of long term adverse affects in man. Carcinogenicity Not known to be carcinogenic. Mutagenicity Not known to be mutagenic. Reproductive Toxicity Major ingredients have not been shown to cause significant fertility or development problems at levels which are not themselves toxic to the animal concerned.One minor ingredient – Methyl di glycol – has been shown to affect foetus development in some studies and is classified as R63 – possible risk of harm to the unborn child. 12. ECOLOGICAL INFORMATION 12.1 Ecotoxicity – Product is of low acute ecotoxicity. Fish 96h LC50 = > 100 mg/l (Oncorhynchus Mykiss) Daphnia 48h EC50 = Not Determined but expected to be virtually non toxic. Algae 72h EC50 = Not Determined but expected to be virtually non toxic. 12.2 Mobility Soluble in water and will partition to aqueous phase. Volatilisation from water to air not expected. Mobile in soil until degraded. 12.3 Persistence/Degradability Product is inherently biodegradable and is expected to be readily biodegradable. OECD 302B (Zahn Wellans/EMPA) = 100% elimination at 21 days. If admitted into adapted biological water treatment plants,no adverse effects on the degrading action of the live sludge are expected. 12.4 Bioaccumulative Potential Not expected to bioaccumulate. Log POW for all main ingredients = < 2.0
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Bulletin Dot 4 Brake Fluid Material Safety Data Sheet 13. DISPOSAL CONSIDERATIONS 13.1 Disposal Dangers Not significant. As for spillages - avoid liquid entering drains, rivers etc. 13.2 Disposal Methods Controlled incineration or recycling is recommended. 13.3 Regulations Dispose of in accordance with local and national regulations. In the E.U. used brake fluids are covered by the Hazardous Waste Directive (91/689/EEC) while the Waste Framework Directive (75/442/EEC) also applies. 14. TRANSPORT INFORMATION 14.1 - UK / EU Regulations
Not classified
14.2 - UN No./Class
None
14.3 - ADR/RID
Not classified
14.4 - IMO/IMDG
Not classified as hazardous
14.5 - Marine Pollutant
No
14.6 - IATA/IACO Class
Not classified
15. REGULATORY INFORMATION 15.1 - E.U. Classification (U.K. CHIP 3) Risk Phrases R36 - Irritating to eyes. Safety Phrases S2 - Keep out of reach of children. S26 (Modified) - In case of contact with eyes, rinse immediately with water for 10 mins. If irritation persists seek medical advice. S46 - If swallowed seek medical advice immediately and show the container or label 15.2 Restrictions on use or Exposure To be in accord with local and national regulations. In the U.K. this would include the HSWA and COSHH. 16. OTHER INFORMATION 16.1 Legal Disclaimer The information contained herein is based on the present knowledge and experience of Brake engineering. It in no way constitutes the users own assessment of work place risk as required by other Health and Safety legislation. Brake engineering does not, by supplying this information, guarantee or warrant any specific properties or qualities of goods supplied.It is the responsibility of the purchaser to determine whether the goods ordered are fit for any purpose for which they may be required. This information is provided subject to Brake engineeringâ&#x20AC;&#x2122;s Conditions of Sale, and in particular Conditions 9 and 14 thereof.
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Bulletin Ford Mondeo Master Cylinder Warning Part Number: MC1455BE Vehicle: Ford Mondeo (with ABS) Year: 02/93 > 02/96 This master cylinder is 98mm long when measured from face of mounting flange to the end by the last outlet. Some models have a longer cylinder of appoximately 120mm in length (MC1043BE). MC1455BE is not to be confused or fitted in place of this longer cylinder. IF FITTED INCORRECTLY, IT WILL ALTER PEDAL TRAVEL AND CAUSE THE BRAKES TO LOCK UP.
98mm
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Block Exemption Regulation Brake Engineering is an original equipment manufacturer of brake components for various UK & European vehicle manufacturers. Where products produced and distributed by Brake Engineering are not manufactured specifically for the vehicle manufacturers these products are produced to the same stringent quality standards. Brake Engineering manufacturers all products under the control of ISO9001:2008 quality system, all parts supplied by Brake Engineering are compliant with EEC Commission Regulation 461/2010 which came into force on 1st June 2010. Brake Engineering prides its self in offering the most comprehensive range of quality braking components to the independent aftermarket. All parts sold are a direct replacement for those fitted to the vehicle by the vehicle manufacturer and in some applications exceed the performance of the original part. Our range of asbestos free brake pads and shoes are also manufactured to the same stringent quality standards and, comply with the latest ECE Regulation R90 directive where applicable (vehicles registered on or after 1999).
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Brake Engineering Redwither Road, Wrexham Industrial Estate, Wrexham LL13 9RD T +44 (0) 1978 667800 F +44 (0) 1978 667801 E sales@brake-eng.com
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