Revised 03-98

$2.50

Automatic Slack Adjuster

Maintenance Manual 4B
Service Notes

Before You Begin

Service Notes
Access Product and Service
This manual provides maintenance and service Information in the DriveTrain PlusTM
procedures for Meritor’s automatic slack adjuster. by ArvinMeritor Tech Library on
Before you begin procedures: arvinmeritor.com
1. Read and understand all instructions and
Go to arvinmeritor.com. Click Products & Services/
procedures before you begin to service
Truck & Trailer Products/Sales & Service/Tech
components.
Library icon. The screen will display an index of
2. Read and observe all Caution and Warning publications by type.
safety alerts that precede instructions or
procedures you will perform. These alerts help To Order Information by Phone
to avoid damage to components, serious
personal injury, or both. Call ArvinMeritor’s Customer Service Center at
800-535-5560 to order the following publications.
3. Follow your company’s maintenance and
service, installation, and diagnostics O Automatic Slack Adjuster Installation and
guidelines. Maintenance (Video 90234)
4. Use special tools when required to help avoid O New Generation Automatic Slack Adjuster
serious personal injury and damage to (Video T-9443V)
components.
O Drivetrain PlusTM by ArvinMeritor Technical
Electronic Library on CD. Features product
Safety Alerts, Torque Symbol and service information on most Meritor,
and Notes ZF Meritor and Meritor WABCO products.
$20. Order TP-9853.

A Warning alerts you to an Meritor Brakes That Use Automatic

instruction or procedure
WARNING that you must follow
Slack Adjusters
exactly to avoid serious O Cam brakes, including Q PlusTM LX500 and
personal injury and MX500 and Cast PlusTM cam brakes
damage to components.
O Air disc brakes
A Caution alerts you to an
instruction or procedure
CAUTION that you must follow
exactly to avoid damage to
components and possible
serious injury.
A torque symbol alerts you
to tighten fasteners to a
specified torque value.
NOTE A Note provides
information or suggestions
that help you correctly
service a component.
 Table of Contents

Asbestos and Non-Asbestos Fibers Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Section 1: Introduction
Meritor’s Automatic Slack Adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
How the Automatic Slack Adjuster Works
Pressed-In, Sealed Actuator Boot on Meritor Automatic Slack Adjusters Manufactured from
July 1998
Factory-Installed Automatic Slack Adjusters on Q PlusTM LX500 and MX500 Cam Brake Packages
Handed and Unhanded Slack Adjusters
Pull Pawls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Clevis Types and Thread Sizes
Section 2: Remove the Slack Adjuster from the Camshaft
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Section 3: Disassembly
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Section 4: Prepare Parts for Assembly
Prepare Parts for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Clean Parts
Dry Parts After Cleaning
Inspect Parts
Corrosion Protection
Automatic Slack Adjusters
Section 5: Assembly
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Section 6: Install the Slack Adjuster Onto the Camshaft
Installing the Slack Adjuster Onto the Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Section 7: Adjust the Brakes
Check Brake Chamber Push Rod Stroke and Adjust the Clevis Position . . . . . . . . . . . . . . . . . . . . . . . . .15
Brake Slack Adjuster Position (BSAP) Method
Automatic Slack Adjuster Templates
Measure the Slack Adjuster
Install a Threaded Clevis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Free Stroke Measurement
Section 8: Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Section 9: Inspection
Commercial Vehicle Safety Alliance (CVSA) Guidelines to Measure Push Rod Travel
(Adjusted Chamber Stroke) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Alternate Method for Determining Push Rod Travel (Adjusted Chamber Stroke)
Commercial Vehicle Safety Alliance (CVSA) North American
Out-of-Service Criteria Reference Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Section 10: Lubrication and Maintenance
Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Anti-Seize Compound
Factory-Installed Automatic Slack Adjusters on Q PlusTM LX500 and MX500 Cam Brake Packages
Maintenance
Inspections and Lubrication
At Brake Reline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Slack Adjusters Manufactured Before 1993
 Asbestos and Non-Asbestos Fibers
Asbestos and Non-Asbestos Fibers

ASBESTOS FIBER WARNING NON-ASBESTOS FIBERS WARNING

The following procedures for servicing brakes are recommended to reduce exposure to The following procedures for servicing brakes are recommended to reduce exposure to
asbestos fiber dust, a cancer and lung disease hazard. Material Safety Data Sheets are non-asbestos fiber dust, a cancer and lung disease hazard. Material Safety Data Sheets are
available from Meritor. available from Meritor.

Hazard Summary Hazard Summary

Because some brake linings contain asbestos, workers who service brakes must understand Most recently manufactured brake linings do not contain asbestos fibers. These brake
the potential hazards of asbestos and precautions for reducing risks. Exposure to airborne linings may contain one or more of a variety of ingredients, including glass fibers, mineral
asbestos dust can cause serious and possibly fatal diseases, including asbestos (a chronic wool, aramid fibers, ceramic fibers and silica that can present health risks if inhaled.
lung disease) and cancer, principally lung cancer and mesothelioma (a cancer of the lining of Scientists disagree on the extent of the risks from exposure to these substances.
the chest or abdominal cavities). Some studies show that the risk of lung cancer among Nonetheless, exposure to silica dust can cause silicosis, a non-cancerous lung disease.
persons who smoke and who are exposed to asbestos is much greater than the risk for Silicosis gradually reduces lung capacity and efficiency and can result in serious breathing
non-smokers. Symptoms of these diseases may not become apparent for 15, 20 or more difficulty. Some scientists believe other types of non-asbestos fibers, when inhaled, can
years after the first exposure to asbestos. cause similar diseases of the lung. In addition, silica dust and ceramic fiber dust are known
Accordingly, workers must use caution to avoid creating and breathing dust when servicing to the State of California to cause lung cancer. U.S. and international agencies have also
brakes. Specific recommended work practices for reducing exposure to asbestos dust determined that dust from mineral wool, ceramic fibers and silica are potential causes of
follow. Consult your employer for more details. cancer.
Accordingly, workers must use caution to avoid creating and breathing dust when servicing
Recommended Work Practices brakes. Specific recommended work practices for reducing exposure to non-asbestos dust
follow. Consult your employer for more details.
1. Separate Work Areas. Whenever feasible, service brakes in a separate area away from
other operations to reduce risks to unprotected persons. OSHA has set a maximum allowable Recommended Work Practices
level of exposure for asbestos of 0.1 f/cc as an 8-hour time-weighted average and 1.0 f/cc
averaged over a 30-minute period. Scientists disagree, however, to what extent adherence to 1. Separate Work Areas. Whenever feasible, service brakes in a separate area away from
the maximum allowable exposure levels will eliminate the risk of disease that can result from other operations to reduce risks to unprotected persons.
inhaling asbestos dust. OSHA requires that the following sign be posted at the entrance to 2. Respiratory Protection. OSHA has set a maximum allowable level of exposure for silica
areas where exposures exceed either of the maximum allowable levels: of 0.1 mg/m3 as an 8-hour time-weighted average. Some manufacturers of non-asbestos
DANGER: ASBESTOS brake linings recommend that exposures to other ingredients found in non-asbestos
CANCER AND LUNG DISEASE HAZARD brake linings be kept below 1.0 f/cc as an 8-hour time-weighted average. Scientists
AUTHORIZED PERSONNEL ONLY disagree, however, to what extent adherence to these maximum allowable exposure levels
RESPIRATORS AND PROTECTIVE CLOTHING will eliminate the risk of disease that can result from inhaling non-asbestos dust.
ARE REQUIRED IN THIS AREA. Therefore, wear respiratory protection at all times during brake servicing, beginning with
2. Respiratory Protection. Wear a respirator equipped with a high-efficiency (HEPA) filter the removal of the wheels. Wear a respirator equipped with a high-efficiency (HEPA)
approved by NIOSH or MSHA for use with asbestos at all times when servicing brakes, filter approved by NIOSH or MSHA, if the exposure levels may exceed OSHA or
beginning with the removal of the wheels. manufacturers’ recommended maximum levels. Even when exposures are expected to be
within the maximum allowable levels, wearing such a respirator at all times during brake
3. Procedures for Servicing Brakes. servicing will help minimize exposure.
a) Enclose the brake assembly within a negative pressure enclosure. The enclosure 3. Procedures for Servicing Brakes.
should be equipped with a HEPA vacuum and worker arm sleeves. With the a) Enclose the brake assembly within a negative pressure enclosure. The enclosure
enclosure in place, use the HEPA vacuum to loosen and vacuum residue from the should be equipped with a HEPA vacuum and worker arm sleeves. With the
brake parts. enclosure in place, use the HEPA vacuum to loosen and vacuum residue from the
b) As an alternative procedure, use a catch basin with water and a biodegradable, brake parts.
non-phosphate, water-based detergent to wash the brake drum or rotor and other b) As an alternative procedure, use a catch basin with water and a biodegradable,
brake parts. The solution should be applied with low pressure to prevent dust from non-phosphate, water-based detergent to wash the brake drum or rotor and other
becoming airborne. Allow the solution to flow between the brake drum and the brake parts. The solution should be applied with low pressure to prevent dust from
brake support or the brake rotor and caliper. The wheel hub and brake assembly becoming airborne. Allow the solution to flow between the brake drum and the
components should be thoroughly wetted to suppress dust before the brake shoes brake support or the brake rotor and caliper. The wheel hub and brake assembly
or brake pads are removed. Wipe the brake parts clean with a cloth. components should be thoroughly wetted to suppress dust before the brake shoes
c) If an enclosed vacuum system or brake washing equipment is not available, or brake pads are removed. Wipe the brake parts clean with a cloth.
employers may adopt their own written procedures for servicing brakes, provided c) If an enclosed vacuum system or brake washing equipment is not available,
that the exposure levels associated with the employer’s procedures do not exceed carefully clean the brake parts in the open air. Wet the parts with a solution applied
the levels associated with the enclosed vacuum system or brake washing with a pump-spray bottle that creates a fine mist. Use a solution containing water,
equipment. Consult OSHA regulations for more details. and, if available, a biodegradable, non-phosphate, water-based detergent. The
d) Wear a respirator equipped with a HEPA filter approved by NIOSH or MSHA for use wheel hub and brake assembly components should be thoroughly wetted to
with asbestos when grinding or machining brake linings. In addition, do such work in suppress dust before the brake shoes or brake pads are removed. Wipe the brake
an area with a local exhaust ventilation system equipped with a HEPA filter. parts clean with a cloth.
e) NEVER use compressed air by itself, dry brushing, or a vacuum not equipped with a d) Wear a respirator equipped with a HEPA filter approved by NIOSH or MSHA when
HEPA filter when cleaning brake parts or assemblies. NEVER use carcinogenic grinding or machining brake linings. In addition, do such work in an area with a local
solvents, flammable solvents, or solvents that can damage brake components as exhaust ventilation system equipped with a HEPA filter.
wetting agents. e) NEVER use compressed air by itself, dry brushing, or a vacuum not equipped with a
4. Cleaning Work Areas. Clean work areas with a vacuum equipped with a HEPA filter or by HEPA filter when cleaning brake parts or assemblies. NEVER use carcinogenic
wet wiping. NEVER use compressed air or dry sweeping to clean work areas. When you solvents, flammable solvents, or solvents that can damage brake components as
empty vacuum cleaners and handle used rags, wear a respirator equipped with a HEPA filter wetting agents.
approved by NIOSH or MSHA for use with asbestos. When you replace a HEPA filter, wet the 4. Cleaning Work Areas. Clean work areas with a vacuum equipped with a HEPA filter or by
filter with a fine mist of water and dispose of the used filter with care. wet wiping. NEVER use compressed air or dry sweeping to clean work areas. When you
5. Worker Clean-Up. After servicing brakes, wash your hands before you eat, drink or empty vacuum cleaners and handle used rags, wear a respirator equipped with a HEPA filter
smoke. Shower after work. Do not wear work clothes home. Use a vacuum equipped with a approved by NIOSH or MSHA, to minimize exposure. When you replace a HEPA filter, wet the
HEPA filter to vacuum work clothes after they are worn. Launder them separately. Do not filter with a fine mist of water and dispose of the used filter with care.
shake or use compressed air to remove dust from work clothes. 5. Worker Clean-Up. After servicing brakes, wash your hands before you eat, drink or
6. Waste Disposal. Dispose of discarded linings, used rags, cloths and HEPA filters with smoke. Shower after work. Do not wear work clothes home. Use a vacuum equipped with a
care, such as in sealed plastic bags. Consult applicable EPA, state and local regulations on HEPA filter to vacuum work clothes after they are worn. Launder them separately. Do not
waste disposal. shake or use compressed air to remove dust from work clothes.
6. Waste Disposal. Dispose of discarded linings, used rags, cloths and HEPA filters with
Regulatory Guidance care, such as in sealed plastic bags. Consult applicable EPA, state and local regulations on
References to OSHA, NIOSH, MSHA, and EPA, which are regulatory agencies in the United waste disposal.
States, are made to provide further guidance to employers and workers employed within the
United States. Employers and workers employed outside of the United States should consult Regulatory Guidance
the regulations that apply to them for further guidance. References to OSHA, NIOSH, MSHA, and EPA, which are regulatory agencies in the United
States, are made to provide further guidance to employers and workers employed within the
United States. Employers and workers employed outside of the United States should consult
the regulations that apply to them for further guidance.

1
 BOOT
RETAINING BOOT
CLAMP
SMALL
CLEVIS PIN
ACTUATOR ROD
PISTON RETAINING Meritor Automatic
LARGE
CLEVIS PIN
RING ACTUATOR Slack Adjuster
ROLLER (PIN) ASSEMBLY
RETAINER CLIP
ACTUATOR PISTON Current Models:
ACTUATOR
January 1993 or Later
(ADJUSTING SLEEVE)
SMALL
LARGE CLEVIS PIN
CLEVIS PIN RETAINER
CLIP
STRAIGHT HOUSING
OR OFFSET
CLEVIS
WORM GEAR
BUSHING
GASKET MANUAL
ADJUSTING
NUT (END
PULL PAWL ASSEMBLY OF WORM)
(Replaces all previous pawl assemblies.)
WORM
RETAINING
RING
FACE WORM
NOTE: Parts shown in this box are SEAL GREASE
not serviceable or interchangeable SEAL
with parts from earlier models. GEAR
GREASE
RETAINER/SEAL FITTING

BOOT BOOT
RETAINING SMALL
CLAMP CLEVIS PIN Models Before
ACTUATOR ROD
January 1993
PISTON RETAINING
RING ACTUATOR
COTTER ASSEMBLY
ROLLER (PIN)
PIN
ACTUATOR PISTON
GEAR
ACTUATOR
RETAINING
(ADJUSTING SLEEVE) THRUST RING
GEAR WASHER
LARGE
COTTER SEAL
CLEVIS PIN
PIN
BUSHING
STRAIGHT OR
OFFSET CLEVIS GASKET

PULL PAWL ASSEMBLY

(Replaces all previous pawl assemblies.) HOUSING

THRUST WASHER WORM GEAR

MANUAL
ADJUSTING NUT
GEAR GEAR (END OF WORM)
RETAINING WORM
RING GEAR GREASE RETAINING
SEAL FITTING RING

WORM
GREASE SEAL

ii
2
 Meritor Automatic
PUSH LARGE
ROD CLEVIS
Slack Adjuster
PIN LARGE CLEVIS PIN
BRAKE AIR CLEVIS RETAINER CLIP Cutaway View
CHAMBER
SMALL CLEVIS PIN
RETAINER CLIP

SMALL CLEVIS PIN

JAM ACTUATOR ROD

NUT
BOOT
COLLAR
BOOT RETAINING
HOUSING CLAMP

PISTON
ROLLER (PIN) RETAINING RING

ACTUATOR ACTUATOR PISTON

(ADJUSTING SLEEVE)

PULL PAWL ASSEMBLY

Correct position for “unhanded” design.
Shown 90˚ out of position for handed design.
GEAR

GASKET

WORM

GREASE FITTING WORM RETAINING

RING

GEAR RETAINER/SEAL WORM GREASE SEAL

MANUAL ADJUSTING
NUT (END OF WORM)

Offset Clevis for

Front Axle Slack Adjuster

OFFSET CLEVIS CLEVIS

LARGE COTTER COLLAR
CLEVIS PIN PIN SPRING

Use with
type 9 and 12
air chambers. LARGE
CLEVIS
PIN

ACTUATOR ROD
SPRING SLACK
ADJUSTER
SMALL ARM
CLEVIS PIN

3
Section 1
Introduction

Meritor’s Automatic
Section 1
Introduction
Pressed-In, Sealed Actuator Boot on
Slack Adjuster Meritor Automatic Slack Adjusters
Manufactured from July 1998
NOTE: As of January 1993 some parts of Meritor’s
A pressed-in, sealed actuator boot is standard
automatic slack adjuster are no longer serviceable
equipment on Meritor automatic slack adjusters
and are not interchangeable with parts from earlier
manufactured from July 1998.
models. Refer to Exploded View, pages 2 and 3, for
more information. The boot features a metal retaining ring with
additional material that extends beyond the base
How the Automatic Slack of the retainer and forms a seal once the boot is
pressed into the slack adjuster body.
Adjuster Works
r Meritor part numbers will not change.
Meritor’s automatic slack adjuster automatically
adjusts the clearance between the brake lining and r All application information is printed on the
the brake drum (rotor). When linings wear, this slack adjuster’s identification tag.
clearance increases and causes the chamber push r A counterbore is machined into the slack body
rod to move a greater distance to apply the brakes. for easier installation of the press-in boot.
When you install an automatic slack adjuster, you
set the brake chamber stroke measurement, which Factory-Installed Automatic Slack
is the correct clearance between the linings and
drum (rotor). Figure 1.1.
Adjusters on Q PlusTM LX500 and
MX500 Cam Brake Packages
During operation, if the chamber stroke exceeds
the design limit, the automatic slack adjuster will Q Plus™ LX500 and MX500 brake packages
automatically adjust the push rod’s return stroke to include factory-installed automatic slack adjusters
control clearance between the lining and drum that do not have grease fittings, and lubrication
(rotor) and reset the stroke to the correct length. intervals differ from conventional slack adjusters.
Refer to Maintenance Manual MM-96173,
Figure 1.1
Q Plus™ LX500 and MX500 Cam Brakes, for
complete information. Call Meritor’s Customer
Service Center at 800-535-5560 to order this
publication.

Handed and Unhanded Slack Adjusters

There are two automatic slack adjuster designs:
HANDED and UNHANDED. For most applications,
install a HANDED automatic slack adjuster so that
the pawl faces INBOARD on the vehicle.
The pawl can be on either side or on the front of
the slack adjuster housing. Figure 1.2.

Figure 1.2

UNHANDED
HANDED

Figure 1.2A Figure 1.2B

PAWL

CONVENTIONAL
PRY UP
PAWL PULL PAWL

4
 Section 1
Introduction

Pull Pawls One-Piece Threaded Clevis

Pull pawls are spring loaded. Pry the pull pawl at Most of Meritor’s automatic slack adjusters,
least 1/32-inch to disengage the teeth. Figure 1.2B. including the factory-installed slack adjusters on
When you remove the pry bar, the pull pawl will the new Q Plus™ LX500 and MX500 cam brakes,
re-engage automatically. have a one-piece threaded clevis.
r The clevis has a threaded hole for the push rod.
Replace Conventional Pawls with Figure 1.4.
Pull Pawls r The one-piece threaded clevis can be straight
When you service an automatic slack adjuster, or offset.
replace a conventional pawl with a pull pawl. r All service replacement automatic slack
Figure 1.2A and Figure 1.2B. Install the slack adjusters have one-piece threaded clevises.
adjuster so that you can remove the conventional
pawl or disengage the pull pawl when you adjust
the brake. Figure 1.4

OFFSET
Clevis Types and Thread Sizes CLEVIS

NOTE: Meritor’s automatic slack adjusters and

clevises are designed to be used as a system.
Always replace original components with genuine
Meritor replacement parts. Although parts from
other manufacturers can look the same, significant
STRAIGHT
differences can exist that can affect brake system CLEVIS
performance.

“Quick Connect” Clevis

THREADS
Some models of Meritor’s automatic slack adjuster
have a “Quick Connect” clevis. Figure 1.3.
r A “Quick Connect” clevis is a three-piece Thread Sizes
assembly that cannot be separated after it
is assembled. Straight and offset clevises are available in two
thread sizes (including metric threads) to match
r The collar has a threaded hole for the push rod. push rod threads.
r A “Quick Connect” clevis can be straight or
offset. Use an offset clevis when more clearance Table A: Thread Sizes
is necessary between the air chamber and the
tire on the front axle. Chambers Thread Sizes
9, 12, 16 1/2"-20 UNF
Figure 1.3
20, 24, 30, 36 5/8"-18 UNF
CLEVIS

RETAINING
RING GROOVE
RETAINING RING
“QUICK CONNECT”
COLLAR
THREADS

5
Section 2
Remove the Slack Adjuster from the Camshaft

Removal
Section 2the Slack Adjuster from the Camshaft
Remove

CAUTION
You must disengage a pull pawl or remove a
WARNING conventional pawl before rotating the manual
To prevent serious eye injury, always wear safe adjusting nut, or you will damage the pawl teeth.
eye protection when you perform vehicle A damaged pawl will not allow the slack adjuster
maintenance or service. to automatically adjust brake clearance. Replace
damaged pawls before putting the vehicle in
WARNING service.
When you work on a spring chamber, carefully 5. Use a wrench to turn the manual adjusting nut
follow the service instructions of the chamber in the direction shown in Figure 2.1. Move the
manufacturer. Sudden release of a compressed slack adjuster away from the clevis.
spring can cause serious personal injury.
Figure 2.1
WARNING
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 can result.
1. If the brake has a spring brake, compress and
lock the spring, so that the brake is released
completely. Check that no air pressure remains
in the service half of the air chamber.
2. If it is necessary to raise the vehicle, use a jack
and support the vehicle with safety stands.

WARNING
When you remove a clevis pin that has a spring, 6. Remove the snap ring and washers from the
hold the spring with pliers. The spring can camshaft. Remove the slack adjuster from the
disengage from the clevis with enough force to camshaft.
cause serious personal injury.
7. Remove the clevis from the push rod if the gap
3. Remove both clevis pins. between the clevis and the collar of a “Quick
4. Remove a conventional pawl or disengage a Connect” clevis exceeds 0.060-inch (1.52 mm).
pull pawl: Use a screwdriver or equivalent tool You do not have to remove the clevis if it is in
to lift the button of a pull pawl assembly at good condition.
least 1/32-inch from the actuator.

6
 Section 3
Disassembly

Disassembly
Section 3
Disassembly 8. Remove the pin from the rod and piston, if
necessary. Figure 3.3.
WARNING Figure 3.3
To prevent serious eye injury, always wear safe
eye protection when you perform vehicle
maintenance or service.
PIN
1. Cut the clamp and remove it from the boot.
Use a new clamp and boot when you assemble
the slack adjuster. PISTON

2. Remove the boot from the housing. Pull the

actuator assembly from the housing.
Figure 3.1.
ACTUATOR ROD
Figure 3.1

NOTE: You do not have to remove the slack

adjuster arm bushing unless it is worn or
“egg-shaped.”
9. Inspect the condition and fit of the slack
adjuster arm bushing.
10. If necessary, install a new bushing onto the
clevis pin. Use the clevis pin and mallet to
drive out the old bushing while you drive in the
new bushing.

NOTE: Steps 11 through 21 apply only to

3. Use a small screwdriver to push down on one automatic slack adjusters manufactured BEFORE
side of the piston retaining ring to force the January 1993. The gear set and seals are not
ring out of the groove. Figure 3.2. serviceable on automatic slack adjusters
4. Extend the coils of the ring. manufactured AFTER January 1993. Refer to the
exploded views on pages 2 and 3 of this manual
5. Use pliers to unwind the ring and pull it out of for more information.
the groove. Figure 3.2.
11. Use a small screwdriver to remove the grease
Figure 3.2 seal from around the worm bore. Figure 3.4.
Discard the seal. Use a new seal when you
assemble the slack adjuster.
Pull ring out.
Push ring down.
Figure 3.4

6. Use a new ring when you assemble the slack

adjuster.
7. Pull the actuator rod, piston and pin from the
actuator.

7
Section 3
Disassembly

12. Use snap ring pliers to remove the retaining 17. Unwind the ring by hand and pull it out of the
ring from the worm bore. Figure 3.5. groove. Figure 3.7.

Figure 3.5 Figure 3.7

NOTCH

13. Use a wrench to turn the manual adjusting nut 18. Remove the thrust washer.
and wind the worm out of the bore. Figure 3.6.
CAUTION
Figure 3.6 Push one seal out of one side of the slack adjuster
housing and the other seal out of the other side of
the housing to avoid damaging the seals.
19. Push the gear out of the housing only far
enough to enable you to remove one gear seal.
20. Push the gear out of the opposite side of the
housing and remove the other seal.
21. Inspect the seals. Discard damaged seals.

14. Remove the retaining rings and thrust washers

from both sides of the gear.
15. Fit a small screwdriver into the notch at the
end of the retaining ring.
16. Remove the end of the retaining ring from the
groove.

8
 Section 4
Prepare Parts for Assembly

Prepare Parts for Assembly

Section 4Parts for Assembly
Prepare
Inspect Parts
1. You must carefully inspect all slack adjuster
WARNING parts, including pawl teeth, for wear and
To prevent serious eye injury, always wear safe damage before you assemble the slack
eye protection when you perform vehicle adjuster.
maintenance or service. 2. Replace any part that is worn or damaged.

WARNING Corrosion Protection

Solvent cleaners can be flammable, poisonous and
cause burns. Examples of solvent cleaners are NOTE: Parts must be clean and dry before you
carbon tetrachloride, emulsion-type cleaners and lubricate them.
petroleum-based cleaners. To avoid serious
personal injury when you use solvent cleaners, 1. If you assemble parts immediately after you
you must carefully follow the manufacturer’s clean them: Lubricate parts with grease to
product instructions and these procedures: prevent corrosion. Parts must be clean and dry
before you lubricate them.
r Wear safe eye protection.
2. If you store parts after you clean them: Apply a
r Wear clothing that protects your skin. corrosion-preventive material. Store parts in a
r Work in a well-ventilated area. special paper or other material that prevents
corrosion.
r Do not use gasoline, or solvents that contain
gasoline. Gasoline can explode.
Automatic Slack Adjusters
r You must use hot solution tanks or alkaline
solutions correctly. Follow the manufacturer’s
instructions carefully. CAUTION
Always replace used clevis pin retainer clips with
new ones when servicing the automatic slack
CAUTION adjuster or chamber. Do not reuse clevis pin
Do not use hot solution tanks or water and retainer clips after removing them. Discard used
alkaline solutions to clean ground or polished clips. When removed for maintenance or service,
parts. Damage to parts will result. clevis pin retainer clips can be bent or “gapped
apart” and can lose retention. Damage to
components can result.
CAUTION
Only use solvent cleaners on metal parts. Damage Check the clevis pins and the bushing in the arm of
to parts will result. the slack adjuster. Replace the pins if they are
worn. Replace the bushing if its diameter exceeds
0.531-inch (13.5 mm).
Clean Parts
1. Use solvent cleaners to clean all automatic
slack adjuster parts that have ground or
polished surfaces; for example, the gear, the
worm and the inner bores of the housing.
2. Use soap and water to clean non-metal parts.
3. Use soft paper or cloth that is free from dirt, oil
or abrasives to dry the parts completely.

Dry Parts After Cleaning

Dry the parts immediately after cleaning. Dry parts
with clean paper or rags, or compressed air.

9
Section 5
Assembly

Assembly
Section 5
Assembly 6. Push the gear out of the opposite side of the
housing only until the other seal groove is
visible. Repeat Steps 4 and 5 to install the
WARNING second seal.
To prevent serious eye injury, always wear safe
eye protection when you perform vehicle 7. Lubricate a thrust washer with grease that
maintenance or service. meets Meritor’s specifications. Refer to
Section 10. Install the washer around the gear.
NOTE: Steps 3 through 11 apply only to automatic 8. Expand the retaining ring coil. Install one end
slack adjusters manufactured BEFORE January of the coil into the groove in the outer diameter
1993. The gear set and seals are not serviceable on of the gear. Work around the gear and press
automatic slack adjusters manufactured AFTER the coil into the groove. Figure 5.2.
January 1993. If you are working on a current
model, skip to Step 10.
Figure 5.2
Refer to exploded view in the front of this manual
for more information.
1. Remove any corrosion-preventive material that
may have been applied to the parts you will
assemble.
2. Use grease to lubricate the gear bore in the
housing.

CAUTION
Follow Steps 3, 4 and 5 exactly when you install
the seals so that the sharp edges of the worm
bore will not damage the seals.
3. Install the gear straight into the bore in the
housing without the seals, keeping one seal 9. Repeat Steps 7 and 8 for the opposite side of
groove outside of the housing. the gear.
4. Install a seal into the groove. Figure 5.1. 10. Install the worm into the bore. Turn the
adjusting nut to wind the worm completely
into the bore. Figure 5.3.
Figure 5.1

Figure 5.3

5. Lubricate the seal with grease that meets

Meritor’s specifications. Compress the seal in
its groove. Push the gear into the housing.

10
 Section 5
Assembly

11. Use snap ring pliers to install the retaining ring 13. If you removed the pin, install it into the rod
into the worm bore. and piston. Figure 5.6.

CAUTION Figure 5.6

Install the seal with the lips OUTSIDE of the bore
and the metal retainer INSIDE of the bore to
prevent contamination from entering the slack
PIN
adjuster housing. Damage to components can
result. Figure 5.4.
PISTON
CAUTION
Do not hit the seal after it reaches the bottom of
the bore. Damage to seal will result.
12. Place the seal directly over the worm bore. Use
ACTUATOR ROD
a hammer and 1-3/16-inch (30.2 mm) diameter
seal driver to install the seal straight into the
bore. Figure 5.5.

Figure 5.4 14. Install the actuator rod and piston assembly
into the actuator (adjusting sleeve).
15. Slide the piston retaining ring over the rod.
16. Extend the coils of the ring.
17. Use a small screwdriver to press one end of
the ring into the groove. Figure 5.7.

Figure 5.7

OUTSIDE INSIDE START BOTTOM COIL RING IN GROOVE

Figure 5.5

18. Keep the coil extended. Press on the ring and

work around the groove until the ring is in the
groove completely.
19. Check to ensure that the ring is installed
correctly in the groove. You cannot pull the
piston out of the actuator if the retaining ring is
installed correctly.

11
Section 5
Assembly

20. Install the actuator assembly into the housing 28. As you turn the adjusting nut in the direction
so that the actuator slides along the worm shown in Figure 5.8, read the torque scale and
splines. rotate the gear 360 degrees (22 turns of the
wrench).
21. Slip the boot over the actuator rod.

NOTE: Do not seal the boot to the tapered part of Figure 5.8
the actuator rod.
22 TURNS
r If the rod has a groove: The top of the boot
must fit into the groove.
r If the rod does not have a groove: Use
silicone sealant to seal the top of the boot to
the round part of the rod.
22. Fasten the bottom of the boot to the housing
with a retaining clamp.
23. Conventional Pawl: Install the pawl assembly ROTATE GEAR 360°
into the housing. Tighten the capscrew to a
torque of 15-20 lb-ft (20-27 N•m).
24. Pull Pawl: Remove the screwdriver or
equivalent tool. The pull pawl will re-engage
automatically. 29. The torque value must remain less than
25 lb-in (2.83 N•m) during the complete
25. Use a grease gun to lubricate the slack adjuster 360-degree rotation of the gear.
through the grease fitting. If necessary, install a
camshaft into the slack adjuster gear to 30. If the torque value remains less than 25 lb-in
minimize grease flow through the gear holes. (2.8 N•m): The slack adjuster is working
correctly.
26. Apply lubrication that meets Meritor’s
specifications until new grease purges from 31. If the torque value exceeds 25 lb-in (2.8 N•m):
around the camshaft splines and from the pawl The slack adjuster is not working correctly.
assembly. Refer to Section 10. Disassemble the slack adjuster.
r Check that the slack adjuster is assembled
CAUTION correctly.
In Step 28 turn the adjusting nut only in the
direction shown in Figure 5.8. If you turn the r Check that parts are aligned correctly.
adjusting nut in the opposite direction while the
pawl is installed, you will damage pawl teeth.
Damaged teeth prevent automatic adjustment.
Replace damaged pawls before putting the vehicle
in service.
27. Use a torque wrench that measures lb-in.

12
 Section 6
Install the Slack Adjuster Onto the Camshaft

Installing the Slack Adjuster

Sectionthe
Install 6 Slack Adjuster Onto the Camshaft

WARNING
Onto the Camshaft When you work on a spring chamber, carefully
follow the service instructions of the chamber
WARNING manufacturer. Sudden release of a compressed
To prevent serious eye injury, always wear safe spring can cause serious personal injury.
eye protection when you perform vehicle 7. If the brake has a spring brake, compress and
maintenance or service. lock the spring to completely release the brake.
No air pressure must remain in the service half
WARNING of the air chamber.
Block the wheels to prevent the vehicle from
moving. Support the vehicle with safety stands. CAUTION
Do not work under a vehicle supported only by Most Meritor automatic slack adjusters
jacks. Jacks can slip and fall over. Serious personal manufactured after January 1990 have lubrication
injury can result. holes in the gear splines. Do not operate the
1. Check the camshaft and bushings and seals for actuator before you install the slack adjuster.
wear and corrosion. Lubricant can pump through the holes and onto
the splines. Damage to components can result.
2. Turn the camshaft by hand to check for smooth
operation. 8. If the automatic slack adjuster gear has a
10-tooth spline, apply anti-seize compound to
3. Repair or replace parts as required. the slack adjuster and cam splines. Use Meritor
4. Apply the service brake and spring brake specified O-637, Southwest SA 8249496 or
several times. Check that the chamber return equivalent lubricants.
spring retracts the push rod quickly and
completely. If necessary, replace the return NOTE: Install the slack adjuster so that you can
spring or the air chamber. remove a conventional pawl or disengage a pull
pawl when you adjust the brake.
5. The new automatic slack adjuster must be the
same length as the one you are replacing. 9. Install the slack adjuster onto the camshaft.
Table B below shows the length of slack Position the slack adjuster so that you can
adjuster that is used with each brake chamber remove the pawl when you adjust the brake.
size. 10. If necessary, install spacing washers and the
6. Place blocks in front of and behind the snap ring at a maximum clearance of
vehicle’s wheels to prevent it from moving. 0.062-inch (1.57 mm).
11. Install the clevis onto the push rod. Do not
Table B: Chamber and Automatic Slack tighten the jam nut against the clevis.
Adjuster Sizes
Length of Size of
Slack Adjuster Chamber
(Inches) (Square Inches)
5 9*, 12*, 16, 20, 24, 30
5-1/2 9*, 12*, 16, 20, 24, 30, 36
6 24, 30, 36
6-1/2 30, 36
*Use an auxiliary spring on slack adjusters used with these
size chambers. A size 9 or 12 chamber return spring cannot
supply enough spring tension to completely retract the slack
adjuster.

13
Section 6
Install the Slack Adjuster Onto the Camshaft

CAUTION CAUTION
You must disengage a pull pawl or remove a Always replace used clevis pin retainer clips with
conventional pawl before rotating the manual new ones when servicing the automatic slack
adjusting nut, or you will damage the pawl teeth. adjuster or chamber. Do not reuse clevis pin
A damaged pawl will not allow the slack adjuster retainer clips after removing them. Discard used
to automatically adjust brake clearance. Replace clips. When removed for maintenance or service,
damaged pawls before putting the vehicle in clevis pin retainer clips can be bent or “gapped
service. apart” and can lose retention. Damage to
components can result.
12. Disengage the pawl. Turn the manual adjusting
nut to align the holes in the slack adjuster arm 15. Install new clevis pin retainer clips to hold the
and the clevis. Figure 6.1. clevis in place. Figure 6.2.

Figure 6.1 Figure 6.2

CLEVIS LARGE CLEVIS PIN
AND
RETAINER CLIP

ACTUATOR LARGE CLEVIS PIN

ROD RETAINER CLIP
P/N 2257-D-1174
ALIGN
HOLES

Disengage a pull pawl

or remove a SMALL CLEVIS PIN
RETAINER CLIP
conventional pawl.
P/N 2257-C-1173
SMALL CLEVIS PIN
AND RETAINER CLIP

13. If the slack adjuster has a welded clevis: Apply

anti-seize compound to the two clevis pins. The clevis pin
Install the clevis pins through the clevis and retainer clips
the slack adjuster. must be fully
installed and
14. If the slack adjuster has a threaded clevis: positioned
Refer to Section 7. around the SIDE
of clevis pin.

14
 Section 7
Adjust the Brakes

Check Brake Chamber Push

Sectionthe
Adjust 7 Brakes
Automatic Slack
Rod Stroke and Adjust the Adjuster Templates
Clevis Position Order the correct automatic slack adjuster template from
Meritor’s Customer Service Center at 800-535-5560.
WARNING
To prevent serious eye injury, always wear safe CAUTION
eye protection when you perform vehicle There are five different installation templates for
maintenance or service. Meritor automatic slack adjusters (Figure 7.2). The
templates are NOT interchangeable. You MUST
NOTE: You cannot adjust the clevis position on a use the correct template and you MUST adjust the
chamber push rod that is equipped with a welded clevis position as described below. If you use the
clevis. wrong template and install the clevis in the wrong
position, the slack adjuster will not adjust the
There are two methods you can use to adjust the brake correctly. If the slack adjuster under-adjusts,
clevis position on a chamber push rod that is then stopping distances are increased. If the slack
equipped with a threaded clevis: adjuster over-adjusts, then the linings may drag
r The Brake Slack Adjuster Position (BSAP) and damage the brake.
method for standard and long stroke chambers.
r Meritor’s automatic slack adjuster template Measure the Slack Adjuster
method for standard stroke chambers only.
NOTE: For long stroke chambers, use the BSAP
method to measure the automatic slack adjuster.
Brake Slack Adjuster Position
(BSAP) Method 1. Use the correct Meritor automatic slack
adjuster template to measure the length of the
When installing the automatic slack adjuster, verify slack adjuster. The marks by the holes in the
that the BSAP dimension of the chamber matches small end of the template indicate the length of
the table in Figure 7.1. the slack adjuster. Figure 7.2.

Figure 7.1 Figure 7.2

3.750" AND 3.812"
BRACKET OFFSET
BSAP ± 0.125"

Color of Part Use to Install

Template Number Slack Adjusters On
Dark TP-4786 Truck or tractor drum brake
SLACK brown
LENGTH
5.00" Tan TP-4787 Trailer drum brake
5.50" White TP-4781 Coach drum brake
6.00"
6.50" Green TP-4788 Disc brake with offset clevis
SLACK ADJ. ± 0.125" LONG Yellow TP-4789 Disc brake with straight clevis
SIZE BSAP STROKE
5.00" 2.75" - Measure slack
5.50" 2.75" 2.25" adjuster
6.00" 2.75" - arm length.
6.50" 2.62" -
Correct position of automatic slack adjuster:
3.750" and 3.812" offsets only. For other
bracket offsets, refer to the vehicle
manufacturer's specifications. CAMSHAFT CENTER

15
Section 7
Adjust the Brakes

Install a Threaded Clevis Table C: Jam Nut Torque Specifications

1. Install the large clevis pin through the large
Threads Torque
holes in the template and the clevis.
1/2-20 20-30 lb-ft (27-41 N•m)
2. Select the hole in the template that matches
the length of the slack adjuster. Hold that hole 5/8-18 35-50 lb-ft (48-68 N•m)
on the center of the camshaft.
3. Look through the slot in the template. If Free Stroke Measurement
necessary, adjust the position of the clevis until
the small hole in the clevis is completely CAUTION
visible through the template slot. Figure 7.3. You must disengage a pull pawl or remove a
conventional pawl before rotating the manual
Figure 7.3 adjusting nut, or you will damage the pawl teeth.
A damaged pawl will not allow the slack adjuster
THREADED
CLEVIS
to automatically adjust brake clearance. Replace
damaged pawls before putting the vehicle in
service.

NOTE: During preventive maintenance on an

SLOT in-service brake, check both the free stroke as
described below and the adjusted chamber stroke
as described in Section 9.
CAMSHAFT END
On some applications, you may find the in-service
free stroke to be slightly longer than specified in
Step 5. However, this is not necessarily a concern,
as long as the adjusted chamber stroke is within
the limits shown in the Commercial Vehicle Safety
4. Check for these specifications: Alliance (CVSA) charts on page 20.

r Thread engagement between the clevis and 1. Disengage a pull pawl or remove a
the push rod must be at least 1/2-inch conventional pawl.
(12.7 mm). Figure 7.4. 2. Turn the adjusting nut in the direction shown in
r The push rod must not extend through the Figure 7.5 until the linings touch the drum, and
clevis more than 1/8-inch (3.18 mm). If then turn the adjusting nut in the opposite
necessary, cut the push rod, or install a new direction:
push rod with a new air chamber. r 1/2 turn for drum brakes
5. Tighten the jam nut against the clevis to torque r 3/4 turn for disc brakes
specifications in Table C.
Figure 7.5
Figure 7.4

MINIMUM 1/2"

MAXIMUM 1/8"

Disengage a
pull pawl or remove
THREADED CLEVIS a conventional pawl.

16
 Section 7
Adjust the Brakes

3. Measure the distance from the center of the 6. If it is necessary to adjust the stroke, turn the
large clevis pin to the bottom of the air adjusting nut 1/8 turn in the direction shown in
chamber while the brake is released. Refer to Figure 7.7 and check the stroke again. Continue
“X” in Figure 7.6. to measure and adjust the stroke until it is
adjusted correctly.
4. Use a pry bar to move the slack adjuster so
that the linings are against the drum (applying 7. Release a pull pawl or install a conventional
the brakes). Measure the same distance again pawl.
while the brakes are applied. Refer to “Y” in
Figure 7.6. Figure 7.7

CAUTION Disengage a
Do not set free stroke shorter than specifications. pull pawl or
If free stroke is too short, linings can drag and remove a
damage the brake. conventional
pawl.
5. The difference between measurement “X” and
measurement “Y” is the free stroke, which sets SHORTEN
the clearance between the linings and drum. STROKE
LENGTHEN
Free stroke must be within the following STROKE
specifications. Figure 7.6.
r Drum Brakes:
1/2-inch – 5/8-inch (12.7-15.9 mm)
r Disc Brakes:
3/4-inch – 7/8-inch (19.1-22.2 mm)

Figure 7.6 WARNING

MEASURE “FREE STROKE” When you work on a spring chamber, carefully
follow the service instructions of the chamber
“Y” manufacturer. Sudden release of a compressed
“X” spring can cause serious personal injury.
8. If the brake has spring chambers, carefully
release the spring.
9. Test the vehicle to ensure that the brake
system is operating correctly before you return
the vehicle to service.

FREE STROKE = “Y” MINUS “X”

Drum brake free stroke must be
1/2" – 5/8" (12.7-15.9 mm).
Disc brake free stroke must be
3/4" – 7/8" (19.1-22.2 mm).

17
Section 8
Diagnostics

Section 8
Diagnostics

Symptoms Possible Causes Corrective Actions

Adjusted stroke is The slack adjuster part number is incorrect. Check with WD or OEM.
too long.
The clevis angle is incorrect. Use correct template or BSAP setting
No adjustment. to install clevis correctly.
Excessive wear exists between the clevis and Replace with threaded clevis.
collar (more than 0.060” [1.52 mm]).
The jam nut at the clevis is loose. Tighten to specification.
There is a worn clevis pin bushing in slack Replace bushing.
arm (ID larger than 0.53" [13.46 mm]).
There is a weak or damaged air chamber Replace return spring or air chamber.
spring. Spring force must be at least
32 lb (142.4 N) at first push rod movement.
The spring brake does not retract fully. Repair or replace spring brake.
There are worn or damaged teeth on the pawl Replace pawl or actuator.
or actuator.
High torque is required to rotate worm when Rebuild or replace slack adjuster.
slack is removed from vehicle.
In service slack maximum worm torque:
45 lb-in (5.09 N•m)
New or rebuilt slack maximum worm torque:
25 lb-in (2.83 N•m)
Excessive looseness exists between the Replace powershaft, gear or automatic
splines of the camshaft and the slack adjuster slack adjuster as needed.
gear.
A cam brake has worn components (cam Replace components.
bushing, for example).
Adjusted stroke is OEM replacement linings are not installed. Use Meritor-approved linings.
too short. Linings exhibit excessive swell or growth.
Linings drag. The slack adjuster part number is incorrect. Check with WD or OEM.
The clevis angle is incorrect. Use correct template to install
clevis correctly.
The jam nut at the clevis is loose. Tighten to specification.
The spring brake does not retract fully. Repair or replace spring brake.
The manual adjustment is incorrect. Adjust brake. Refer to Section 7.
Poor contact exists between the linings and Repair or replace drums or linings.
the drum. The drum is out-of-round.
Brake temperature is not even. Correct brake balance.
Figure 8.1

18
 Section 9
Inspection

Commercial Vehicle Safety

Section 9
Inspection 4. With the brakes released, mark the push rod
where it exits the chamber. Figure 9.1.
Alliance (CVSA) Guidelines to Measure and record the distance.
Measure Push Rod Travel 5. Have another person apply and hold the brakes
(Adjusted Chamber Stroke) one full application. Figure 9.1.
6. Measure push rod travel distance (adjusted
Use the following procedures to check in-service chamber stroke) from where the push rod exits
push rod travel (adjusted chamber stroke) on truck the brake chamber to your mark on the push
or tractor air brakes with automatic slack adjusters. rod. Measure and record the distance.
Hold the ruler parallel to the push rod and measure Figure 9.1.
as carefully as possible. An error in measurement 7. To determine push rod travel (adjusted
can affect CVSA re-adjustment limits, which state chamber stroke): Subtract the measurement
that “any brake 1/4-inch or more past the you obtained in Step 4 from the measurement
re-adjustment limit, or any two brakes less than you obtained in Step 6. The difference is the
1/4-inch beyond the re-adjustment limit will be push rod travel (adjusted chamber stroke).
cause for rejection.”
r Push rod travel (adjusted chamber stroke)
WARNING must not be greater than the stroke length
shown in the CVSA reference charts for the
To prevent serious eye injury, always wear safe size and type of air chamber you are
eye protection when you perform vehicle inspecting.
maintenance or service.
r If push rod travel (adjusted chamber stroke)
WARNING is greater than the maximum stroke shown
in the CVSA reference charts, inspect the
When you work on a spring chamber, carefully slack adjuster and replace it if necessary.
follow the service instructions of the chamber
manufacturer. Sudden release of a compressed
spring can cause serious personal injury. Alternate Method for Determining
1. The engine must be OFF. If the brake has Push Rod Travel (Adjusted
spring chambers, carefully release the spring. Chamber Stroke)
2. Check the gauges in the cab to ensure that air Use the above procedure, except in Step 4 and
pressure in the tanks is 100 psi (689 kPa). Step 6, measure the distance from the bottom of
3. Determine the size and type of brake chamber the air chamber to the center of the large clevis pin
you are inspecting. on each of the brakes.

Figure 9.1

Mark push rod here STROKE

to measure stroke.

• Spring brakes • Spring brakes

released released
• Service brakes 100 psi (689 kPa) in air • Service brakes
not applied tank — engine OFF applied

19
Section 9
Inspection

Commercial Vehicle Safety Alliance (CVSA) North American

Out-of-Service Criteria Reference Charts
NOTE: A brake found at the adjustment limit is not
a violation.

Table D: “Standard Stroke” Clamp-Type

Brake Chamber Data
Outside
Diameter Brake Adjustment
Type (inches) Limit (inches)
6 4-1/2 1-1/4
9 5-1/4 1-3/8
Should be
12 5-4/16 1-3/8 as short as
16 6-3/8 1-3/4 possible
without
20 6-25/32 1-3/4 lining to
24 7-7/32 1-3/4 drum
contact
30 8-3/32 2
36 9 2-1/4
* For 3" maximum stroke type 24 chambers

Table E: “Long Stroke” Clamp-Type

Brake Chamber Data
Outside
Diameter Brake Adjustment
Type (inches) Limit (inches)
16 6-3/8 2.0 Should be
as short as
20 6-25/32 2.0
possible
24 7-7/32 2.0 without
lining to
24* 7-7/32 2.5 drum
30 8-3/32 2.5 contact

20
 Section 10
Lubrication and Maintenance

Lubricants
Section 10 and Maintenance
Lubrication

Table F: Conventional Automatic Slack Adjuster Grease Specifications

Meritor NLGI Outside
Component Specification Grade Grease Type Temperature
Automatic Slack O-616-A 1 Clay Base Down to -40°F (-40°C)
Adjuster
O-692 1 and 2 Lithium Base Down to -40°F (-40°C)
O-645 2 Synthetic Oil, Clay Down to -65°F (-54°C)
Base
Clevis Pins Any of Above See Above See Above See Above
O-637 1-1/2 Calcium Base Refer to the grease
manufacturer’s specifications
O-641 — Anti-Seize for the temperature service
limits.

Anti-Seize Compound Maintenance

Meritor lubricant specification O-637 (part number
2297-U-4571) is a corrosion control grease. Do not Inspections and Lubrication
mix this grease with other greases. This
compound is also available from the Southwest Inspect and lubricate the slack adjuster according
Petro-Chemical Division of Witco Chemical to one of the following schedules. Use the
Corporation, 1400 South Harrison, Olathe, KS schedule that gives the most frequent inspection
66061, as “Corrosion Control,” part number and lubrication. Also inspect and lubricate the
SA 8249496. slack adjuster whenever you reline the brakes.

r Use anti-seize compound on the clevis pins of r The schedule of chassis lubrication used by
all slack adjusters. your fleet.

r Also use anti-seize compound on the automatic r The schedule of chassis lubrication
slack adjuster and cam splines if the slack recommended by the chassis manufacturer.
adjuster gear has no grease groove and holes r Every six months.
around its inner diameter.
r A minimum of four times during the life of
the linings.
Factory-Installed Automatic Slack
Adjusters on Q PlusTM LX500 and
MX500 Cam Brake Packages
Q Plus™ LX500 and MX500 cam brake packages
include factory-installed automatic slack adjusters
that do not have grease fittings, and lubrication
intervals differ from conventional slack adjusters.
Refer to Maintenance Manual No. MM-96173,
Q Plus™ LX500 and MX500 Cam Brakes, for
complete information. Order this publication by
calling Meritor’s Customer Service Center at
800-535-5560.

21
Section 10
Lubrication and Maintenance

At Brake Reline Slack Adjusters Manufactured

1. Before you perform brake maintenance, check Before 1993
the free stroke and the adjusted chamber 1. Remove the slack adjuster when these
stroke as described in Section 7. conditions are apparent:
2. If the free stroke is not correct, refer to the r The grease is dry or contaminated.
Diagnostics table on page 18 to correct the
stroke before you adjust the chamber stroke. r The pawl or actuator is worn.
3. Inspect the boot for cuts or other damage. If 2. Disassemble the slack adjuster.
the boot is cut or damaged, remove the pawl 3. Replace any worn or damaged parts.
and inspect the grease.
4. Use new seals and a new boot when you
4. If the grease is in good condition, replace the assemble the unit.
damaged boot with a new boot.
5. Use a grease gun to lubricate the slack adjuster
through the grease fitting. If necessary, install a
camshaft into the slack adjuster gear to
minimize grease flow through the gear holes.
6. Lubricate until new grease purges from around
the inboard camshaft splines and from the
pawl assembly.
7. Measure the gap between the clevis and the
collar on a “Quick Connect” clevis. Replace the
clevis if the gap exceeds 0.060-inch (1.52 mm).
Figure 10.1.

Figure 10.1

0.060" (1.52 MM) MAXIMUM

GAP BETWEEN
COLLAR AND CLEVIS

22
Meritor Heavy Vehicle Systems, LLC Information contained in this publication was in effect at the time the publication was approved for printing and is
2135 West Maple Road subject to change without notice or liability. ArvinMeritor Commercial Vehicle Systems reserves the right to revise
Troy, MI 48084 USA the information presented or discontinue the production of parts described at any time.
800-535-5560
arvinmeritor.com Copyright 1998 Maintenance Manual 4B
ArvinMeritor, Inc. Revised 03-98
All Rights Reserved Printed in the USA 16579/24240