D-Elsa 2 Reaction Beam Air Disc Brake: Maintenance Manual No. MM-1130

an ArvinMeritor brand
Maintenance manual no. MM-1130

D-Elsa 2 Reaction Beam Air Disc Brake
Revised July 2003
Service Notes
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This publication provides installation and maintenance procedures Site
for the D-Elsa 2 Reaction Beam Air Disc Brake. Additional maintenance and service information for ArvinMeritor's
commercial vehicle systems component lineup is also available at
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Meritor uses the following notations to alert the user of possible

safety issues and to provide information that will help to prevent
damage to equipment and components.
WARNING
A WARNING indicates a procedure that you must follow
exactly to avoid serious personal injury.
CAUTION
A CAUTION indicates a procedure that you must follow
exactly to avoid damaging equipment or components.
Serious personal injury can also occur.
NOTE: A note indicates an operational, procedure or instruction

that is important for proper service. A NOTE can also supply
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2 ArvinMeritor Air Disc Brake D-ELSA 2

Contents
pg. 05 Section 1: Introduction

06 Axial brake D-ELSA 2 - exploded view
07 Axial brake D-ELSA 2 - parts list
08 Radial brake D-ELSA 2 - exploded view
09 Radial brake D-ELSA 2 - parts list
10 Cross section
11 Caliper body detail - cross section
12 Electronic continuous wear sensor - cross section
13 How it works
17 Section 2
18 Pad replacement
25 Section 3
26 Caliper replacement
29 Section 4
30 Bridge replacement
31 Section 5
32 Housing replacement
35 Section 6
36 Piston dust excluder replacement
39 Section 7
40 Guide sleeve, dust excluder & bush replacement
51 Section 8
52 Servicing and specifications
53 Section 9 : Service tools

54 Bush fitting tool
55 Rubber bush fitting tool
ArvinMeritor Air Disc Brake D-ELSA 2 3

Terms used in this manual
Manufacturer: Warranty
ARVINMERITOR Warranty applies to the air disc brake installed on vehicles for
which it was designed. Warranty is void in the following cases:
Manual:
Maintenance manual no. MM-1130 • Improper use of the vehicle on which the air disc brake is
installed (usage conditions, overloading etc.)
Device:
D-Elsa 2 Reaction Beam Air Disc Brake • Tampering with vehicle components that may affect brake
performance.
Technician:
Qualified personnel working on brake maintenance and servicing. • Use of non-original spare parts.
Maintenance and servicing: • Improper installation, adjustment, repair or modification.

Maintenance and servicing refer to periodical checks and/or
• Poor or improper maintenance (including consumables other
replacement of air disc brake parts or components. It also refers
than those specified).
to the determining of the cause of a malfunction in order to
restore the initial operating conditions.
Operator: Further information on warranty conditions may be obtained

Any person who will use the air disc brake as part of a more directly from the manufacturer or by referring to the ArvinMeritor
complex device. web site www.arvinmeritor.com
Introduction
1
pg. 06 Axial brake D-ELSA 2 - exploded view
07 Axial brake D-ELSA 2 - parts list
08 Radial brake D-ELSA 2 - exploded view
09 Radial brake D-ELSA 2 - parts list
10 Cross section
11 Caliper body detail - cross section
12 Electronic continuous wear sensor - cross section
13 How it works

Exploded view
Axial brake D-ELSA 2

D-Elsa 2 axial brake parts list
Ref Description
1 Bridge
2 Carrier
3 Pad
4 Pad spring
5 Screw
6 Pad Retaining Plate
7 Tappet Head
8 Tappet Excluder
9 Piston Housing Assembly Screw
10 Piston Housing Assembly
11 Gasket
12 Guide Sleeve Excluder
13 Guide Sleeve Excluder Retainer
14 Guide Sleeve Bush (Plain)
15 Visual Pad Wear Indicator
16a Guide Sleeve Bush (Oval)
16b Guide Sleeve Bush (Rubber)
17 Manual Override Stem Assembly
18 Housing
19 Roller
20 Bearing
21 Operation Shaft
22 Half Bearing
23 Saddle
24 Guide Sleeve (Long)
25 Guide Sleeve Screw (Long)
26 Oval Guide Sleeve (Short)
26a Plain Guide Sleeve (Short)
27 Guide Sleeve Screw (Short)
28 End Cap
29 Bridge Screw
30 Seal
31 Manual Override Stem Seal
32 Manual Override Stem Cap Retainer
33 Manual Override Stem Cap
34 Continuous Wear Sensor or Wear Switch
35 Retaining Screw

Exploded view
Radial brake D-ELSA 2

D-Elsa 2 radial brake parts list
Ref Description
1 Bridge
2 Carrier
3 Pad
4 Pad spring
5 Screw
6 Pad Retaining Plate
7 Tappet Head
8 Tappet Excluder
9 Piston Housing Assembly Screw
10 Piston Housing Assembly
11 Gasket
12 Guide Sleeve Excluder
13 Guide Sleeve Excluder Retainer
15 Visual Pad Wear Indicator
16 Guide Sleeve Retainer
17 Guide Sleeve Bush (Oval)
18 Manual Override Stem Assembly
19 Housing
20 Roller
21 Bearing
22 Operation Shaft
23 Half Bearing
24 Saddle
25 Guide Sleeve (Long)
26 Guide Sleeve Screw (Long)
27 Guide Sleeve (Short)
28 Guide Sleeve (Short)
29 End Cap
30 Bridge Screw
31 Seal
32 Manual Override Stem Seal
33 Manual Override Stem Cap Retainer
34 Manual Override Stem Cap
35 Continuous Wear Sensor or Wear Switch
36 Retaining Screw

Cross section
8 37
10
9
1
5 36
35
32
30
4
15
34
31
18
7
33 2 3

Cross section
Caliper body detail
19 27 28 26 38 20 16 18
41
17
15
2 13 29 25 24 12 14
11

Cross section
Electronic continuous wear sensor
22
23
21
39 40

1 Introduction
Introduction
The air actuated disc brake has been designed to incorporate a

direct mounted air chamber which is mounted axially as shown in
Fig. 6 and radially mounted as shown in Fig. 6a.
The caliper, detailed in the exploded view, can be fitted to either

front or rear axles and can be used for vehicle parking when a
service/spring brake chamber is fitted.
The basic operation of the caliper is simple, but it is important

that the features of the load insensitive automatic adjuster are
clearly understood.
Fig. 6
It is essential that the correct service procedures be observed to
ensure that the caliper gives satisfactory service throughout its
working life.
How it works
(Refer to Cross Sections - page 9, 10, 11)
The air chamber/actuator is attached to the caliper body and

operates directly onto the internal operating shaft assembly, thus
removing the necessity for the conventional external lever and
linkage arrangement. Sealing between actuator and caliper is
achieved by seals located in the caliper coverplate and actuator
assembly. The carrier, secured to the vehicle, straddles the disc
and supports the brake pads. The body assembly slides on two Fig. 6a
fully sealed guide sleeves bolted to the brake carrier.
As the pads wear, adjustment takes place automatically and

independently of load.
NOTE: “Load Independent” means adjustment takes place under

very small clamping forces only, therefore preventing over-
The housing and bridge slide on 3 bushes (30,31,32) which are
adjustment and minimising air consumption.
pressed in to the housing (2). On the short guide sleeve side (4),
the sleeve itself is oval to accommodate brake deflection during
Two guide sleeves (4,7) are bolted on to the brake carrier (1) by braking, note on the later brakes the ovality is transferred from
means of guide sleeve screws (5,6). The brake carrier is the guide sleeve to the bush, whereas the longer sleeve (7)
connected to the stub axle. The housing (2) is mounted so that it provides a more positive location for the housing. The guide
floats on the guide sleeves and a bridge (8) is fixed to the housing sleeves are sealed externally by dust excluders (35,36) and two
(2) to provide the reaction force on the outboard pad (10). end caps (33,34).

1 Introduction
The force introduced from the air chamber is amplified by the Automatic adjustment
geometry of the operating shaft (3). This clamping force is The automatic adjuster makes an adjustment to the operation of
transferred to the inboard pad (9) via the half-bearings (11,12), the brake pad to compensate for pad wear. Every time the brake
the rollers (13,14), the tappets (15,16), the pistons(17,18) and is applied, the system senses whether adjustment is required or
the piston heads (19,20). Once the inboard pad (9) has been whether the running clearance of the brake pads to the brake
applied, the force of reaction acting through the floating housing disc is still within the built-in tolerance and does not need to be
(2) and bridge (8) pulls the outboard pad (10) on to the brake disc adjusted.
(37).
The built in tolerance is determined in the design by the clearance
The forces created by the friction of the brake pads on the brake between the ball-ended drive pin (24) that is rigidly fixed to the
disc are transferred at the ends of the pads on to the carrier (1), operating shaft and the fork on the end of the adjuster shaft (25).
which is rigidly mounted to the axle.
a) Operation without adjustment
The brakes are released by reducing the input force on the From the rest position, the push rod of the air cylinder moves
operating shaft (3), thus reducing the clamp force of the brake. forward, rotating the operating shaft. Just as the pistons (17,18)
have moved forward by the inbuilt running clearance, the ball-
The return spring (38) then returns the clamping mechanism and
ended drive pin (24) starts to contact the driving side of the fork
the operating shaft back to their starting position, leaving the
on the end of the adjuster shaft (25). Further movement of the air
pads with a defined running clearance to the disc.
chamber push rod rotates the operating shaft (3), now causing
The small run-out of the brake disc and hub-bearing clearances the adjuster shaft (25) to rotate because the inbuilt clearance has
will then generate a small clearance for the outboard pad (10) been taken up. The outer drive sleeve (26) is fixed to the adjuster
through only a few revolutions of the disc. shaft (25) and rotates the inner drive sleeve (28) via the clutch
pack (27). The inner drive sleeve (28) is linked to the intermediate
In some applications, an Electronic Continuous Wear Sensor (23)
gear (29) by a unidirectional friction spring (38) and this tries to
is fitted. This is shown in figure 2 (Elsa 2 Sectioned View Power
rotate the tappets (15,16). However, the friction in the threads of
point - Fig. 5 page 11) and constantly monitors the distance
the tappets (15,16) and pistons (17,18) has started to increase
across the pads and the disc, allowing the system to monitor and
due to the clamping force on the pads and this prevents the
adjust brake balance as pad wear is recorded. The wear sensor
pistons and tappets rotating relative to one another. The pistons
(23) is driven by an arm (22) that runs up and down a fine thread
cannot rotate in their housing (41) and due to the high torque to
on the manual adjuster stem (21). The arm cannot rotate within
turn the tappets (15,16) the clutch pack (27) ‘slips’, preventing
the housing (2) and as adjustment of the brake mechanism
adjustment of the mechanism below the correct running
occurs, the manual adjuster stem (21) rotates and the arm travels
clearance.
up the length of the shaft, driving the sensor.

1 Introduction
b) Operation with adjustment c) Manual adjustment and de-adjustment during a pad

As a result of pad or disc wear, the running clearance is now change
greater than the inbuilt tolerance and adjustment of the Manual adjustment of the brake must only be made at a pad
mechanism is now required. From the rest position, the push rod change. No manual intervention is required between pad
of the air cylinder moves forward, rotating the operating shaft (3). changes.
Just as the pistons (17,18) have moved forward by the inbuilt
A manual adjuster shaft (21) runs in constant mesh with the gear
running clearance, the ball-ended drive pin (24) starts to contact
form on the outside of the tappets (15,16). The end of this stem
the driving side of the fork on the end of the adjuster shaft (25).
comes out from the brake housing through a seal (39) and is
Further movement of the operating shaft, now causes rotation of
protected further by an adjuster cap (40).
the adjuster shaft (25) via the ball-ended drive pin (24). Driving
through the clutch pack (27) and the unidirectional friction spring To increase the gap between the piston heads (19,20) and the
(38), the intermediate gear (29) rotates. Due to the excessive bridge (8) in order to fit new pads, remove the adjuster cap (40)
running clearance the tappets now rotate in the pistons. The and rotate the shaft (21) in an anti-clockwise direction.
pistons (17, 18) cannot rotate and are, therefore, wound out from
After fitting new pads an initial running clearance needs to be set
their housing (41). When the pads finally contact the disc, the
and some manual adjustment may be required. To reduce the gap
clamping force increases the thread friction in the tappets (15,
between the piston heads (19,20) and the bridge (8), remove the
16) and pistons (17,18). The torque to turn the tappets (15,16)
adjuster cap (40) and rotate the shaft (21) in a clockwise direction
then increases and the clutch pack (27) driving the intermediate
until the desired clearance is achieved. Replace the adjuster cap
gear (29) starts to slip, preventing further adjustment. The
(40).
adjustment is not wound back during the return of the actuation
mechanism. As the operating shaft (3) now returns to the brakes-
off position, the ball-ended drive pin (24) travels back through the
clearance in the fork on the end of the adjuster shaft (25). Once
this clearance is taken up, the adjuster shaft (25) then rotates in
the reverse direction, rotating the inner drive sleeve (28) via the
clutch pack (27). However, in this direction, the unidirectional
friction spring (38) cannot drive the intermediate gear (29),
leaving the tappets (15,16) and intermediate gear (29) in the
adjusted state. The system is now once again in its starting
position.

Pad replacement
2
pg. 18 Pad replacement

2 Pad replacement
Pad Replacement
The Elsa 2 Air Disc Brake uses a number of devices to monitor

pad wear. These fall into 2 categories:
1. Device fitted to the body of the brake

2. Device fitted in the pad area.
The variations depend on the vehicle specification. Listed below

are the variations that will be encountered when servicing the
brake.
Category 1 Fig. 7
A. Continuous wear sensor

This device is used in conjunction with electronic braking system.
Its function is to continuously monitor the pad and rotor wear and
feed this information to the electronic system. Fig. 7 identifies a
brake fitted with a continuous wear sensor.
B. Wear switch
The wear switch is fitted in place of a continuous wear sensor.
The wear switch will indicate a fully worn pad via a light within
the cab. Fig.8 shows a brake fitted with a wear switch.
C. Pad wear out indicator (visual indication)

This is a simple device which indicates the amount of pad
material remaining with reference to a plunger which protrudes
from the housing. Fig. 9 shows a brake fitted with a pad wear out Fig. 8
indicator.
In the new pad condition the end of the indicator stem will extend
past the face of the brake housing casting. As the pads wear the
length of indicator visible past the edge of the casting will reduce.
When the amount protruding from the casting reduces to a
measurement of 4 mm then detailed examination of the pad
material remaining is required.
Fig. 9

2 Pad replacement
Category 2
PWWI Early version (two types)
This device will light a warning lamp in the cab to indicate that a
pad change is required - Fig. 10
NOTE: The later version is interchangeable with the above

version and should be used as a replacement whenever possible.
Pad wear indicator

Fig. 11 shows an alternative assembly. Both these earlier versions
are replaced by the one later version.
Pad wear indicator - later version

This version is a direct replacement for the earlier version. Fig. 12
Fig. 10
When replacement of a PWWI is required the later level should be
used. It is interchangeable with the old level.
Pad replacement
Brake pad should be replaced when the lining thickness has worn
to 1.5 mm. Always replace brake pads in axle sets.
Park the vehicle on hard ground and chock the road wheels.
Apply air pressure and fully charge the system to ensure the park
brake is fully released. Wind off the spring brake retraction screw
(where appropriate). Jack up the axle and fit suitable axle stands
securely. Remove the road wheels and exhaust all air from the
system. Remove any dirt from the caliper assembly. Ensure the
rubber dust excluders fitted to the tappet heads and guide
sleeves are not damaged.
Fig. 11
CAUTION
Never use an air line to blow dust from the brake/disc area.
If inhaled any form of dust can at best be an irritant, at
worst dangerous. Whenever 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.
Fig. 12

2 Pad replacement
Pad removal (old level PWWI)

Remove the pad retaining plate screw - Fig. 13
Remove the pad strap from the slot in the caliper casting but do
not attempt to remove it further at this stage.
Remove pad springs. Carefully remove both plastic blocks from

their location in the pads. Do not use excessive force as this may
result in damage. - Fig. 14
It is now possible to remove the pad strap and PWWI assembly as

far as the connecting cable will allow. Ensure that this cable is not
stretched.
Fig. 13
Removal of later level PWWI
NOTE : With this version the PWWI is separate from the pad
strap.
Remove the pad strap by removing the pad retaining screw as

described in the previous section. Remove both pad springs.
Carefully remove both plastic blocks from their location in the
pads. Do not use excessive force as this may result in damage.
Fig. 15
Carefully lever out the plastic rivet holding the PWWI assembly to
the caliper body. Fig. 16 - The complete PWWI assembly can now
be placed aside ensuring that the connecting cable is not
stretched. Fig. 14
Fig. 16 Fig. 15

2 Pad replacement
Pad removal
It may be necessary to de-adjust the brake initially to remove the
worn brake pads. Remove the adjuster stem protecting cap.
Locate a suitable 10 mm socket spanner on the adjuster stem
and rotate the spanner in an anticlockwise direction as viewed
from the air chamber side. Fig. 17
WARNING
Always de-adjust/adjust the brake carefully by hand with a
suitable spanner. Never exceed a maximum torque of 40 Nm Fig. 17
in either direction and NEVER use power tools.
Remove the brake pads.

Fitting New Pads
De-adjust the brake until with the housing pulled across there is a
Cleaning and inspection
sufficient aperture to fit the outboard pad.
With the brake pads removed check the integrity of the guide
sleeve and tappet excluders. They should be secure and free from Fit the new outboard pad. Fig. 18
any signs of damage. If damaged they should be replaced by
following the procedures laid out in Sections 6 and 7. Check that
the caliper housing assembly slides freely on the guide sleeves.
WARNING
Take care not to trap fingers whilst checking the sliding
action of the brake.
Examine the brake disc for corrosion, grooving and signs of deep
cracks. If there is any doubt in the serviceability of any component
refer to the vehicle manufacturer for corrective action. Whilst
wearing suitable eye protection remove all traces of scale, dirt
etc, from the pad apertures /abutment faces and around the edge
of the disc, particularly that encroaching onto the braking area.
A scraper or old screwdriver supported on the caliper body whilst

the disc is rotated will remove most of the corrosion. Finish off if
necessary with emery cloth. Remove all traces of scale, dirt etc, Fig. 18
from pad apertures and abutment faces that may restrict the
movement of the pads and, therefore, prevent sufficient
adjustment of the brake.

2 Pad replacement
Push the housing back towards the disc until the new pad
contacts the disc face. Continue to de-adjust the brake until the
aperture gap between the tappet heads and the disc face is large
enough to accept the new inboard pad. With the brake fully de-
adjusted it may be necessary to lift the tappet boots to release
any trapped air which may be inflating the dust excluder ( Fig. 19)
Fit the inboard pad.

To adjust the brake locate a 10mm socket on the adjuster stem
and turn it clockwise viewed from the back of the brake. Continue
to adjust the brake until the pads grip the rotor. De-adjust the
brake by 1/2 a turn of the spanner. Ensure the disc is free to turn.
Fig. 19
WARNING
Do not exceed 40Nm torque on the adjuster stem.
Refit PWWI and Pad Strap - Old Level.
NOTE: Old levels are no longer available and should only be re-
used if there is no damage or wear to the wires or plastic blocks.
Carefully hold the pad retaining plate complete with PWWI in its
location to allow fitment of the plugs. Fig. 20 Fig. 20
Fit the plastic blocks of the PWWI into the pads. Do not use
excessive force but ensure they are pushed to the bottom of the
slot. Fig. 21
Fig. 21

2 Pad replacement
Refit both pad springs ensuring that they are correctly located in
the pads back plates. Fig. 22
Ensure that the wires exit to the back of the pad.
Insert the pad retaining plate together with the PWWI assembly
into the slot in the brake housing .
Refit the pad retaining screw and torque to 33-40Nm. Fig. 23
New Level PWWI

Fig. 22
WARNING
Where a new level PWWI replaces the old level,lever out the
5mm rivet and cable clip on the top of caliper housing. Use a
small screwdriver for this task.
Insert the PWWI assembly into the hole in the brake frame.
Fig. 24
Push in the plastic rivet which holds the PWWI assembly to the
brake housing. Fig. 25
Fig. 23
Fig. 24 Fig. 25

2 Pad replacement
Fig. 26 Fig. 28
Fit the plastic blocks of the PWWI into the pads. Fig. 28 shows a PWWI on a LH brake.
Do not use excessive force. Fig. 26
Fit the pad retaining strap and torque to 33-40Nm. Fig. 29
Refit both pad springs ensuring that they are located correctly in Reconnect the PWWI to vehicle wiring. Insert wear sensor or wear
the pads. Fig. 27 switch as appropriate and torque retaining screw to 33-40 Nm.
The PWWI is not a handed assembly and as such the routing of Charge the air system and apply the brakes 5 times to settle the
the wires is different LH to RH. pads and allow the auto adjuster to set the correct running
clearance.
Check that the rotor is free to rotate.
Fig. 27 Fig. 29

Caliper replacement
3
pg. 26 Caliper replacement

Caliper replacement
Park the vehicle on hard ground and chock the road wheels.
Apply air pressure to release the park brake and wind off the
spring brake retraction screw (where appropriate). Jack up the
axle and fit suitable axle stands securely. Remove the road wheels
and exhaust all air from the system. Remove any dirt from the
caliper assembly, ensure the rubber dust excluders are not
damaged.
CAUTION
Never use an air line to blow dust from the brake/disc area.
If inhaled any form of dust can at best be an irritant, at Fig. 30
worst dangerous. 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.
The brake assembly will be fitted with one of the following wear
indicators, which need to be disconnected before removing the
caliper.
1. Continuous wear sensor

Remove the wear sensor retaining screw and carefully lever out
the sensor assembly. Fig. 30 Fig. 31
2. Wear Switch
The wear switch has a separate connector which can be
disconnected leaving the switch in situation in the brake
assembly. Fig. 31
3. PWWI
Disconnect the PWWI plug when a PWWI is fitted.
Remove the air chamber from the caliper housing by removing
the 2 nuts. Fig. 32
Fig. 32

Cover the exposed air chamber mounting aperture in the housing

to prevent debris etc. entering the housing. - Fig. 33
Remove the pads as described in the Pad Replacement section.

The caliper can now be removed from the vehicle by removing the
carrier mounting screws following the vehicle manufacturers
instructions.
NOTE: The caliper assembly is heavy, approximately 49kg

(108lbs). Ensure you have the help of an assistant and the weight
of the caliper is supported when removing the fixing screws to
avoid possible damage to the threads.
Fig. 33
CAUTION
When lifting the caliper assembly avoid trapping fingers
between the caliper housing and carrier which are free to
slide relative to each other. Also prevent any sudden
movement which may result in rapid sliding of the
components which may cause damage to rubber dust
excluder areas.
Caliper Fitment
Ensure all mounting faces are clean and free from corrosion.
With the help of an assistant, carefully lower the caliper assembly Fig. 34
into position on the stub axle mounting.
Avoid excessive movement of the caliper during location and do Offer the air chamber to the housing assembly ensuring the
not allow the caliper to drop into position on the stub axle, either mounting faces and push rod are clean and the push rod is
action could result in damaged dust excluders. Fit new retaining correctly located in the operating shaft pocket.
screws and torque to the vehicle manufacturers
Torque the nuts to 180-210 Nm
recommendations.
Refit the pads as described in the Pad Replacement Section.
Remove the temporary cover from the air chamber aperture.
Lightly grease the operating shaft pocket with the appropriate Refit the Wear Sensor/Wear Switch or PWWI as appropriate.
grease. Fig. 34
WARNING
Only use the grease supplied with replacement
components/kits. Under no circumstance should any other
type of grease be used.

Removing the Bridge
4
pg. 30 Removing the Bridge

4 Removing the Bridge
Removing the Bridge Replace if in any doubt, following procedure laid out in Section 7.
Remove the pads and PWWI where fitted as described in Section
Pay special attention for correct location (arrow A) and any boot
2 “Pad Replacement”. Support the bridge by hand and loosen the
damage, such as splits or tears (arrow B). Fig. 38
4 bridge screws. Fig. 35
Remove and discard these screws (they are not reusable).

Remove the bridge. Fig. 36 Fitting the Bridge.
Locate the bridge in position against the caliper housing.
NOTE: Ensure the housing does not slide off the guide sleeves.
Whilst supporting the weight of the bridge fit the 4 new retaining
Ensure that the mating surface of the housing is clean. Check the screws. Tighten all screws to the torque specified in Section 8.
guide sleeve excluders for signs of damage and secure location.
Fit the brake pads following the procedure detailed in Section 2
Fig. 37
“Pad replacement”.
Fig. 35 Fig. 37
Fig. 36 Fig. 38

Housing replacement
5
pg. 32 Housing replacement

Housing replacement
Support the vehicle and remove the air chamber as detailed in the If any doubt exists as to the suitability for further service replace
“Caliper Removal” section. with new guide sleeves and if necessary a new carrier.
Remove the pads as described in Section 2 “Pad Replacement”. Clean and inspect the brake disc as detailed in the “Pad
Replacement” section.
Remove the bridge as described in Section 4 “Bridge
Replacement”.
Carefully slide the housing off the guide sleeves, which are Fitting a new housing
secured to the carrier. Fig. 39 Lightly lubricate the inner surfaces of the guide sleeve excluders
with grease and ensure they are located correctly on the carrier.
Clean and inspect the carrier for signs of damage or wear paying
Fig. 41 and 42
particular attention to the pad abutment areas and guide sleeves.
Fig. 40
Fig. 39 Fig. 41
guide sleeve
pad abutment
Fig. 40 Fig. 42

Apply grease to the guide sleeve and housing guide sleeve bores. WARNING
Fig. 43 Take care not to damage the guide sleeve excluders when
locating the housing on to the carrier.
NOTE: Only use the grease supplied with the replacement
components/kits. Under no circumstance should any other type of
grease be used. Ensure the dust excluders are located correctly on both carrier
and housing retainers. Fig. 46
Carefully slide the housing assembly into position on the guide
sleeves secured to the carrier. Fig. 44 Slide the housing backwards and forwards several times to check
the smooth movement of the housing on the guide sleeves.
Do not forget the visual wear indicator and spring if fitted.
Locate the guide sleeve excluders onto the housing retainers.

Fig. 45
Fig. 43 Fig. 45
Fig. 44 Fig. 46

long guide sleeve
Fig. 47 Fig. 48
Using a copper faced mallet carefully tap one of the new end
caps into the housing until it retains itself.
Using a suitable sized tool (socket) tap the end cap in until they
stop at the end of their bores in the housing. Fig. 47 short guide sleeve
Repeat for the second end cap.
The end caps for the long and short pins will be fitted to a
different dimension as shown in Figs 48 & 49.
The dimensions must be checked to ensure that they do not

exceed the stated max figures. Check again the free movement of
the housing assembly on the guide sleeves.
Slide the housing backwards and forwards several times to check Fig. 49
the smooth movement of the guide sleeves. Slide the housing to
check the location of the dust excluders. Fig. 50
Refit the Bridge as described in Section 4 “Bridge Replacement”.
WARNING
Always use new bridge screws.Once removed bridge screws
should not be re-used.
Re-assemble the brake as described in Section 3 “Caliper

Replacement”. Refit the pads as described in Section 2 “Pad
Replacement”. Refit the air chamber as described in Section 3
Fig. 50
“Caliper Replacement”.

Piston dust excluder removal and
replacement
6
pg. 36 Piston dust excluder removal and replacement

6 Piston dust excluder removal and replacement
Fig. 51 Fig. 52
Tappet excluder removal and replacement

Remove the brake pads as described in Section 2 “Pad
replacement”. Using the manual override stem adjust out the
piston assemblies. Fig. 51
Adjusting out the brake aids removal of the tappet boots. Fig. 52
Remove the piston boot dust excluders.
Clean the piston heads and housing retainers with a suitable

brake cleaner, or clear methylated spirits. Check for damage to
both areas.
Check condition of tappet pistons. If excessive corrosion or wear

is present, the housing should be replaced. Fig. 53
Fitting new dust excluders
WARNING
Do not use any other type of grease.
Carefully feed one of the new dust excluders over a piston head.
Fig. 53
Do not at this stage fit the boot into the groove in the caliper
housing.
Fit boot into groove on piston head. Fig. 54 Fig. 54

6 Piston dust excluder removal and replacement
The next stage is to stretch the boot using 2 fingers. Fig. 55
With the boot stretched it is then pulled over and fitted to the
groove in the caliper housing. Fig. 56
It is essential that the boot is fitted correctly.
This is best achieved by rotating the boot and checking for

Fig. 55
uniform bead fitment into the grooves. Fig. 57
Figure 58 shows and incorrectly fitted boot.
Repeat the operation for the second piston boot.
De-adjust the brake and refit the pads as described in Section 2

“Pad replacement”.
Fig. 56
correct incorrect
Fig. 57 Fig. 58

Guide sleeve, dust excluder,
retainer and bush
7
pg. 40 Guide sleeve, dust excluder, retainer and bush

7 Guide sleeve, dust excluder, retainer and bush
NOTE: The following are checks that enable the wear on the slide
system to be established with the brake assembly in position on the
vehicle.
Checking slide pin bush wear
Tangential Test
Remove the pads as described in the Pad Replacement Section.
Pull the housing towards the wheel flange. Refer to Fig. 59
Attach a dial gauge (2),whereby the line (3) represents an Fig. 59

extension of the centre line of the short guide sleeve. This gauge
should be attached to the hub. Fig. 60
Hold the housing in such a way that point (5) cannot move and
swivel the housing to the stop in one direction (arrow 1).
Set the gauge to zero.
Move the housing in the opposite direction to the stop as before.
NOTE: Max acceptable reading is 3mm.

If this figure is exceeded then the guide sleeves and bushes
require attention as detailed in the remainder of this section.
Fig. 60
Radial test
Remove the pads as described in the “Pad Replacement” -
Section 2.
Mount a dial gauge in position on the vehicle hub and set against
the housing as shown in Fig. 61.
Position the caliper in the half worn pad position.
This is set when a gap of approximately 20 mm exists between

rotor and bridge.
Hold the caliper at the outboard pad edge and by the air chamber.
Fig. 61

Swivel the caliper by hand in the direction of the arrow (1), as

shown in Figs 61 and 62, as far as possible.
Set the gauge to zero. Swivel the housing as far as possible in the
opposite direction without allowing the caliper to slide.
NOTE: Max acceptable reading is 2.0 mm

If this figure is exceeded then the guide sleeve and bushes
require attention as detailed in the following pages.
Remove the brake pads as described in Section 2 “Pad

Replacement”.
Fig. 62 Remove the Bridge as described in Section 4 “Bridge

Replacement”.
Remove the housing assembly as detailed in Section 5

“Housing Replacement”.
Transfer the caliper housing to a suitable workbench.
Remove the guide sleeve end caps. Fig. 63
NOTE : The process of removing the guide sleeve bushes from

the housing will at the same time remove the dust excluder
retainers, which are pressed into the mouth of the housing guide
sleeve bores.
Fig. 63

Guide Sleeve Bush & Retainer removal.

plain bush Description
There are three types of short Guide Sleeves that can be found on
the Elsa 2 Disc Brake.
1. An oval guide sleeve with a plain bush and separate dust

excluder retainer (Fig. 64).
2. A plain guide sleeve with an oval bronze bush and separate

dust excluder retainer (Fig. 65).
3. A plain guide sleeve with an oval rubber bush and integral

dust excluder retainer (Fig. 66).
Fig. 64
NOTE: Type 1 is not interchangeable with types 2 and 3,

bronze bush although the procedure for fitting the dust excluder retainer in
types 1 and 2 is the same.
Dismantle Guide Sleeves
NOTE: For types 2 and 3 mark alignment of bush on housing as

in Fig. 67. This is important for correct alignment of new bush
when fitting.
Tolerance for fitment is ±4° from the horizontal plane between

the 2 guide sleeve bores. - Fig. 67
Fig. 65
rubber bush
Fig. 66 Fig. 67

Before pressing the bushes out with a suitable bung check the
alignment of the oval bush and then mark the housing so that the
new bush can be correctly aligned before fitment (Fig.68).
Using suitable drift tools press or drift out the bushes from both
housing guide sleeve bores together with the dust excluder
retainers. Fig. 69
NOTE: Clean the guide sleeve bores with a suitable brake

cleaner or clear methylated spirits. Examine the condition of the
bores for wear corrosion or damage. If there is any doubt in the
suitability for further service replace with a new housing
assembly.
Fig. 68
Fitting a guide sleeve bush - Short bore Type 1

For Type 1 (plain bush) place the new bush onto a suitable arbor
from the ArvinMeritor Service Tool MBT 1000. Insert into the
housing bore.
Pull the bush into the guide sleeve bore to a depth of 10mm from
the end of the guide sleeve excluder retainer side of the bore
using remaining parts of ArvinMeritor Service Tool MBT1000 Fig.70
The correct position of the bush can be confirmed by measuring

the distance from the top edge of the bush to the edge of the
machined chamfer in the guide sleeve bore. This should be 10
mm. Fig. 71
Fig. 69
Fig. 70 Fig. 71

Fitting guide sleeve bushes

Short bore types 2 & 3.
Align new bush with markings on housing, bronze bush fig.72
and rubber bush fig. 73.
Place the bush onto ArvinMeritor Service Tool MBT 1011 and
insert into the housing bore.
Bronze bush
For the bronze bush. Pull the bronze bush into the guide sleeve bore
to a depth of 10mm from the end of the guide sleeve excluder
retainer side of the bore using remaining parts of ArvinMeritor
Fig. 72
Service Tool MBT 1000. - Fig. 74
Rubber bush
For the rubber bush, pull the bush into the guide sleeve bore until
the chamfer on the steel case contacts the housing. Fig. 75.
Fig. 73
Fig. 74 Fig. 75

Fitting guide sleeve bushes - Long bore

Place one of the new bushes onto a suitable arbor from the
Meritor service tool MBT 1000. Insert into the housing bore from
the actuator side.
Pull the bush into the guide sleeve bore to a depth of 10mm from
the end of the guide sleeve excluder retainer side of the bore.
Repeat this process with the second bush.
Pull the bush into the guide sleeve bore until it is a 1mm from the
dust excluder retainer seating counterbore. Fig. 79
Fig. 76
Fitting New Dust Excluder Retainers for types 1 & 2.

Using service tool MBT1000, place retainer onto suitable arbor
(Fig. 76)
Place retainer onto housing and with remaining applicable parts

of the service tool draw the retainer into the guide sleeve bore
until chamfered face contacts housing (Figs 77 & 78)
WARNING
Do not apply excessive force when pulling the retainer into
the bore as this may result in damage to the bush or Fig. 77
retainer.
Fig. 78

The correct position of the bush can be confirmed by measuring

the distance from the top edge of the bush to the edge of the
machined chamfer in the guide sleeve bore,actuator side.
This dimension should be 1.0 mm. Fig. 79
NOTE: Do not apply excessive force when pulling the bush/s into
the housing as this may result in damage to the bush or dust
excluder retainer.
Fig. 79 Guide sleeve & dust excluder removal.

Carefully detach the guide sleeve excluders from their location on
the carrier and slide off the guide sleeves. - Fig. 80.
NOTE: It is possible that the guide sleeve excluders remain

attached to the caliper housing retainers and are therefore
removed with the housing.
Remove the guide sleeve screws retaining the guide sleeves to

the carrier. Fig. 81 - If necessary carefully release the guide
sleeves using a rubber or soft metal hammer from their location
on the carrier. Clean the guide sleeve contact areas and threaded
holes in the carrier. Check for wear. Replace the carrier if in
doubt.
Fig. 80
Fitting new guide sleeves & dust excluders

Lightly lubricate the new guide sleeves and the guide sleeve
excluders, on the inside only,with the grease provided in the
service kit.
NOTE: Only use the grease supplied with the replacement

components/kits. Under no circumstances should ant other type
of grease be used. Locate the longer guide sleeve and Types 2
and 3 of the shorter guide sleeve on the carrier and loosely retain
with guide sleeve screws. The Type 1 shorter guide sleeve has an
oval profile and it is important that it is secured to the carrier in
the correct position.
Fig. 81

Turn the guide sleeve until the flat sides are in a vertical plane in
line with the carrier abutment. Use a suitable open ended spanner
to hold the pin in its correct orientation. Fig. 82
Placing a straight edge across the pad abutment shoulder will

help with alignment. Fig. 83
With the guide sleeve correctly aligned tighten the guide

sleeve screw to a torque that is specified in Section 8, under
“Tightening Torques”.
The longer guide sleeve and types 2 and 3 short guide sleeves
Fig. 82 need no alignment. Locate in position on the carrier and secure
with guide sleeve screws.
Tighten the screw to a torque of 495-585Nm.
Fitting new dust excluders

Lightly lubricate the inner surfaces of the guide sleeve excluders
with grease and ensure they are located correctly on the carrier.
Figs. 84 and 85
Fig. 83
Fig. 84 Fig. 85

Apply grease to the guide sleeve and housing guide sleeve bores.
Fig. 86
WARNING:
Only use the grease supplied with the replacement
components/kits. Under no circumstance should any other
type of grease be used.
Carefully slide the housing assembly into position on the guide

sleeves secured to the carrier. Fig. 87
Do not forget the visual wear indicator and spring if fitted. Locate
the guide sleeve excluders onto the housing retainers. Fig. 88
Fig. 86
NOTE: Take care not to damage the guide sleeve excluders
when locating the housing on to the carrier.
Ensure the dust excluders are located correctly on both carrier

and housing retainers. Fig. 89
Slide the housing backwards and forwards several times to check

the smooth movement of the guide sleeves. Using a copper
faced mallet, carefully tap one of the new end caps into the
housing until it retains itself.
Fig. 87
Fig. 88 Fig. 89

Using a suitable sized tool (socket) tap the end cap in until they
stop at the end of their bores in the housing. Fig. 90 Repeat for
the second end cap.
The end caps long and short pins will be fitted to a different
dimension as shown in Figs. 91 and 92
The dimensions must be checked to ensure that they do no

exceed the stated max figures. Check again the free movement of
the housing assembly on the guide sleeves.
Slide the housing backwards and forwards several times to check

the smooth movement of the housing on the guide sleeves.
Fig. 90 Slide the housing to check the location of the dust excluders.
Fig. 93
Refit the bridge as described in the Section 4 “Bridge
long guide replacement”
sleeve
CAUTION
Always use new bridge screws. Once removed bridge
screws should no be re-used.
Refit the pads as described in Section 2 “Pad replacement”
Refit the air chamber as described in Section 3

“Caliper replacement”.
As a final check always apply the brake 5 times to allow the auto
Fig. 91
adjuster to set the correct running clearance.
short guide
sleeve
Fig. 92 Fig. 93

Servicing and Specifications
8
pg. 52 Servicing and Specifications

8 Servicing and Specifications
Tightening Torque’s
Component Torque
M20 Guide Sleeve Screw 485 - 585 Nm
M18 Guide Sleeve Screw (long) 430 - 440 Nm
M18 Guide Sleeve Screw (short) 430 - 440 Nm
Adjuster Stem 40 Nm Maximum
Pad Retaining Plate Screw 33 - 40 Nm
M10 Wear Sensor/Switch Retaining Screw 33 - 40 Nm
Air Chamber Retaining Nut 180 - 210 Nm
Bridge Screws 300 - 350 Nm
Grease Specification NOTE: Only use the grease supplied with replacement
components/kits or that specified by the vehicle manufacturer.
WARNING
Under no circumstance should any other type of grease be used.
Under no circumstances should another grease be used on
this disc brake other than specified. Every 12 months
Remove the road wheels and brake pads as described in the pad
There are 2 types of grease used in the varying levels of this disc
replacement section. Inspect the guide sleeve and tappet
brake. According to the level of the brake, this will define the
excluders and ensure they are undamaged and securely located.
correct grease which will be supplied within the relevant genuine
If any of the dust excluders are detached or damaged the relevant
spare parts kit .
area of the brake should be dismantled and the components
Grease examined for corrosion or damage. Replace/rectify in accordance
Castrol Optitemp TT1EP with the vehicle manufacturers recommendations. Check the
Fushs Unitemp 2 housing assembly slides easily on the guide sleeves secured to
the carrier. If the housing does not slide easily on the guide
Servicing
sleeves remove from the carrier as described in the housing
Although there is no routine maintenance of the caliper required it
replacement section. Examine the guide sleeves and bushed
is important the following inspections are carried out at the
housing guide sleeve bores for signs of corrosion or wear. If there
periods specified, or those detailed in the vehicle manufacturers
is any doubt in the suitability for further service replace with new
manual.
components.
Every 3 months or 20,000 Km.
A visual assessment of pad life remaining should be made. Brake
pads should be replaced when the lining thickness has worn to
1.5 mm. Visually inspect the general condition of the brake
CAUTION
Take care not to trap fingers whilst checking the sliding
assembly for damage or corrosion. If there is any doubt in the
action of the brake.
suitability for further service replace/rectify in accordance with the
vehicle manufacturers recommendations. Check the brake disc for signs of heavy grooving, cracking or
corrosion and the thickness dimension is in accordance with the
vehicle manufacturers recommendations. Replace as necessary.

Service tools
9
pg. 54 Service tools

9 Service tools
The following tools can be purchased from ArvinMeritor Aftermarket
MBT 1000 Bush fitting tool

9 Service tools
MBT 1011 Rubber Bush fitting tool

Meritor Heavy Vehicle Braking Systems
Grange Road, Cwmbran Printed in Italy
South Wales NP44 3XU - U.K.
Tel.: +44 (0) 1633 834238 © Copyright 2002 Issued 10/2002
Fax: +44 (0) 1633 834191
www.arvinmeritor.com ArvinMeritor Inc. M-graph - MM1130

D-Elsa 2 Reaction Beam Air Disc Brake: Maintenance Manual No. MM-1130

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an ArvinMeritor brand

Maintenance manual no. MM-1130

Before You Begin Access Information on ArvinMeritor's Web

You must use special tools, when required, to avoid serious

Meritor uses the following notations to alert the user of possible

NOTE: A note indicates an operational, procedure or instruction

This symbol indicates that you must tighten fasteners to a

2 ArvinMeritor Air Disc Brake D-ELSA 2

pg. 05 Section 1: Introduction

53 Section 9 : Service tools

ArvinMeritor Air Disc Brake D-ELSA 2 3

Maintenance and servicing: • Improper installation, adjustment, repair or modification.

Operator: Further information on warranty conditions may be obtained

ArvinMeritor Air Disc Brake D-ELSA 2 5

6 ArvinMeritor Air Disc Brake D-ELSA 2

ArvinMeritor Air Disc Brake D-ELSA 2 7

8 ArvinMeritor Air Disc Brake D-ELSA 2

ArvinMeritor Air Disc Brake D-ELSA 2 9

10 ArvinMeritor Air Disc Brake D-ELSA 2

ArvinMeritor Air Disc Brake D-ELSA 2 11

12 ArvinMeritor Air Disc Brake D-ELSA 2

The air actuated disc brake has been designed to incorporate a

The caliper, detailed in the exploded view, can be fitted to either

The basic operation of the caliper is simple, but it is important

The air chamber/actuator is attached to the caliper body and

fully sealed guide sleeves bolted to the brake carrier.

As the pads wear, adjustment takes place automatically and

NOTE: “Load Independent” means adjustment takes place under

ArvinMeritor Air Disc Brake D-ELSA 2 13

14 ArvinMeritor Air Disc Brake D-ELSA 2

b) Operation with adjustment c) Manual adjustment and de-adjustment during a pad

ArvinMeritor Air Disc Brake D-ELSA 2 15

ArvinMeritor Air Disc Brake D-ELSA 2 17

The Elsa 2 Air Disc Brake uses a number of devices to monitor

1. Device fitted to the body of the brake

The variations depend on the vehicle specification. Listed below

A. Continuous wear sensor

C. Pad wear out indicator (visual indication)

18 ArvinMeritor Air Disc Brake D-ELSA 2

NOTE: The later version is interchangeable with the above

Pad wear indicator

Pad wear indicator - later version

ArvinMeritor Air Disc Brake D-ELSA 2 19

Pad removal (old level PWWI)

Remove pad springs. Carefully remove both plastic blocks from

It is now possible to remove the pad strap and PWWI assembly as

Removal of later level PWWI

Remove the pad strap by removing the pad retaining screw as

20 ArvinMeritor Air Disc Brake D-ELSA 2

Remove the brake pads.

A scraper or old screwdriver supported on the caliper body whilst

ArvinMeritor Air Disc Brake D-ELSA 2 21

Fit the inboard pad.

Refit PWWI and Pad Strap - Old Level.

22 ArvinMeritor Air Disc Brake D-ELSA 2

Ensure that the wires exit to the back of the pad.

Refit the pad retaining screw and torque to 33-40Nm. Fig. 23

New Level PWWI

ArvinMeritor Air Disc Brake D-ELSA 2 23