Product Information Letter

PRODUCT INFORMATION LETTER
Meritor WABCO
Vehicle Control Systems
2135 West Maple Road
Troy, MI 48084-7121
PRODUCT INFORMATION LETTER #505
DATE: July 14, 2009

SUBJECT: Test procedure to periodically check actuators fitted to DiscPlus EX225
air disc brakes.
MODELS: All vehicles fitted with DiscPlus Ex225 air disc brakes
This document applies to all vehicles fitted with DiscPlus 225 Brakes and more specifically,
vehicles which operate in areas where road salts or de-icing materials are used.

Meritor WABCO recommends that an inspection of the internal condition of the brake and brake
actuator be conducted on a regular basis. The frequency of this inspection is based on fleet
experience.
Although the brake and brake actuator are sealed corrosion in the air chamber seal area could
lead to corrosion of the brake mechanism. Meritor WABCO has developed the following
procedure to inspect for such damage without the need to remove the brake actuator.
Procedure:
1. Park the vehicle on hard ground and chock the road wheels. Where necessary, to gain
access, jack up the axle and fit suitable axle stands securely.
WARNING
To prevent serious eye injury, always wear safe eye protection when you perform vehicle
maintenance or service.
Park 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.
2. Remove any dirt from the brake assembly; ensure the rubber dust excluders are not
damaged.
WARNING
Never use an air line to blow dust from the brake/disc area. If inhaled any form of dust can
irritate the throat and lungs or result in injury. When ever possible remove dry brake dust
with a vacuum brush. Alternatively wipe the areas with a damp cloth; never try to accelerate
drying time by using an air line.
3. Remove the wear sensor plug retaining bolt. Carefully lever out the sensor plug and
place to one side with the bolt for refitment later. (Fig 1, Fig 2 and Fig 3)

Meritor WABCO
Troy, MI 48084-7121

Fig 1 Fig 2
4. Clean the sensor/switch access hole (Fig 4) and mounting face on the housing with a
clean cloth and ensure no debris is allowed to fall into the exposed aperture in the
housing. Lightly grease the ‘O’ ring seals on the vacuum test adaptor plug. Fit the
adaptor plug (Fig. 6) into the housing, and press into place. Fit the retaining screw and
tighten down. 24.3-29.5 lbs-ft (33-40Nm).
Fig 3 Fig 4
CAUTION:
Only use the grease supplied with replacement components/kits, or that specified by the
vehicle manufacturer. Under no circumstance should any other type of grease be used.
(Fig 6)
NOTE:
Ensure the adjuster cover retaining strap is not trapped under the adaptor plug. (Fig 5)

Meritor WABCO
Troy, MI 48084-7121

Fig 5
Fig 6 Vacuum test adapter plug (MST1504) and Fig 7 Conical connectors
grease (68966091)
Fig 8 Adaptor and connector fitted Fig 9 Vacuum tester in position

Meritor WABCO
Troy, MI 48084-7121
5. Using a suitable vacuum tester, such as a “Mityvac”, select the conical connector from
the test kit that fits the hole in the adaptor plug and insert it in the adaptor plug. (Figs 7
and 8).
6. Connect the vacuum tester to the connector using the tubing supplied with the vacuum
tester (Fig 9).
7. Hold the conical connector firmly in place in the test adaptor plug to ensure a good seal

is made between the connector and the plug.
8. While holding the connector actuate the tester observing whether a vacuum is
generated.
If a vacuum is generated do not exceed a value of -5inHg. Stop pumping and observe
whether the vacuum is held or starts to decay.
If a vacuum is generated and held proceed to SECTION A

If a vacuum decays or no vacuum is generated then proceed to SECTION B
SECTION A
If a vacuum is generated and held then no further investigation needs to be
made. Lever out the test adaptor. Lightly grease the ‘O’ ring seal on the wear
sensor plug and refit to housing.
NOTE:
Ensure the adjuster cover retaining strap is not trapped under the adaptor plug.
(Fig 5)
Fit the retaining screw and tighten to a torque value of 24.3-29.5 lbs-ft (33 –
40Nm).
SECTION B
If no vacuum is generated or the vacuum decays then this indicates the air
chamber internal boot is compromised the air actuator may be removed from the
brake for further inspection.
In these circumstances the actuator must be replaced.

Visually inspect the actuator-mounting aperture on the caliper housing assembly
(Fig 11).

Meritor WABCO
Troy, MI 48084-7121
If there are signs of water entry and corrosion replace both the caliper
housing and air actuator.

Fig 10 Corrosion on ball end of actuator and liner part of seal Fig 11 Corrosion inside the brake housing
When fitting a service replacement caliper housing and air actuator refer to the MM-0467
for the detailed procedure.
9. After conducting either Section A or Section B procedure described in instruction 8, to

ensure that the brake and air actuator are working correctly a brake adjustment
inspection is recommended.
Brake Adjustment Inspection
CAUTION
Before you check for correct brake adjustment, verify that the wrench will not be obstructed
by the air chamber, hoses or other brake or axle components. Damage to the brake can
result.
1. To check for correct brake adjustment, deadjust the brake. By using a 10 mm wrench to
rotate the adjuster stem one-quarter turn COUNTERCLOCKWISE.
2. With the 10 mm wrench on the adjuster stem, actuate the brake one time. Figure 12.

Meritor WABCO
Troy, MI 48084-7121
If the wrench rotates CLOCKWISE when you actuate the brake: The adjuster
mechanism is working correctly.
If the wrench does not rotate CLOCKWISE when you actuate the brake: The adjuster
mechanism is not working correctly. Replace the caliper housing assembly per procedure
outlined in maintenance manual MM-0467.

Fig 12.
Once completed charge the system with air. Refit the road wheels, remove the axle stands and
lower the vehicle to the ground.
NOTE:
Before driving the vehicle or applying the park brake, apply the service brake five times at low
pressure to ensure correct adjustment of the pads.

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