Use this as basis for the tabbed file

Replacement of the tappet boot seal assemblies (ref. MEI kit 5R0400 & 5R0405) can be done with the brake fitted to, or removed from, the vehicle using the MEI brake tool kit (ref. 5K0010 or equivalent).

! The use of impact drivers / air wrenches is not permitted with the service tools.

1. Remove the brake pads. Adjust the tappets forwards using a 10mm ring spanner or socket wrench on the adjuster (do not exceed 25 Nm torque) until the tappet boots are easily accessible. The tappets must not be extended more than 30 mm from the caliper face to ensure the pistons remain synchronised. With a suitable lever (e.g. screwdriver) carefully prise the tappet boot out. Take care not to damage the sealing surface on the caliper cover plate.

Note: as the tappet boot is being replaced it may aid visibility and access to cut the rubber material away.

Service Tappet1

2. Position the forked wedge tool (M01) between the threaded piston and the tappet boot seal assembly with the stepped side towards the tappet boot. Carefully drive it down with a hammer to release the tappet boot seal assembly from the threaded piston. Keep the tool perpendicular to the piston – do not lever the tappet or damage the piston thread.

Service Tappet2

3. Remove the tappet bush from the end of the threaded piston. Clean and check the cover plate sealing face and the threaded pistons for damage or corrosion. The pistons and cover plate cannot be replaced and if damaged the caliper should be replaced.

Service Tappet3

4. Wind back the threaded pistons using a 10mm ring spanner or socket wrench on the adjuster (do not exceed 25 Nm torque). Clean the area of the inner boot and carefully remove the inner boot using a suitable lever (e.g. screwdriver). Take care not to damage the sealing face on the caliper cover plate.

! Opening or dismantling the caliper any further will invalidate the warranty.

Service Tappet4

5. Wind out the threaded pistons using a 10mm ring spanner or socket wrench (do not exceed 25 Nm torque) to a maximum extension of 30 mm. Check the pistons for damage or corrosion. If there are signs of water ingress beyond the inner boots the caliper must be replaced. Lubricate the piston threads with WHITE grease (ref. 5F1500). Fully wind back the pistons and fit new inner boots over the threaded pistons carefully pushing them into position in the cover plate.

Service Tappet5

6. Ensure that the old tappet bush is removed. Position tool combination M02 & M03 over the boss of the threaded piston and wind out until M03 touches the brake disc. If the caliper is removed from the vehicle add tool M04 (between M02 & M03) and wind out until M03 touches the outboard pad abutment face of the caliper.

tappet 6a illustrator

7. Press the inner boot over the threaded piston. Use a 27mm A/F spanner to turn M03 against the brake disc until it stops whilst stabilising M02 using a second spanner. Remove the tool and repeat for the second piston. Check for correct fitment of the inner boots: wind out the threaded pistons approx. 10mm by turning the adjuster with a 10 mm ring spanner. Check that the inner boots do not rotate with the threaded pistons. If the inner boot rotates, then the boot must be removed and the procedure repeated using a new inner boot.

tappet 6b illustrator

8. Clean and check the cover plate sealing face and the threaded pistons for damage or corrosion – these cannot be replaced and if damaged the caliper must be replaced. Lubricate the inner abutment face of both tappet heads with BLACK grease (ref. 5F1505) being careful not to transfer the grease to other components.

! Only use the correct grease provided in the MEI repair kit.

tappet 8 illustrator

9. Fully wind back the threaded pistons using a 10mm ring spanner on the adjuster until they stop – do not exceed 25 Nm torque – and then wind forward one full turn. Fit a new tappet bush onto the boss of both of the threaded pistons. Fit the new tappet boot seal assemblies over the tappet bushes on the threaded pistons, pushing them into position. To complete the fitment of the tappet boot seal assemblies, use tool combination M03, M05 & M06 for fitment on the vehicle, adding tool M04 (between M03 & M05) if the brake is removed from the vehicle.

! Tool M07 in MEI tool kit 5K0010 is not required for MEI calipers.

tappet 9 illustrator

10. Position tool combination M03, M05 & M06 so that the closed side of M06 touches the brake disc. Wind out M03 using a spanner to press the tappet boot seal assembly until it stops.

tappet 10 illustrator

11. If the caliper is removed from the vehicle then add tool M04 (between M03 & M05) so that the closed side of M06 touches the outboard pad abutment face and wind out M03 using a spanner to press the tappet boot seal assembly until it stops.

tappet 11 illustrator

12. Release the tool and turn tool M06 over, within M05, so that the open side of M06 makes contact with the tappet boot seal. Ensure it is centralised on the tappet.

tappet 12 illustrator

13. If the caliper is removed from the vehicle then add tool M04 (between M03 & M05). Press the tappet boot seal into place by winding out M03 against the brake disc, or the outboard pad abutment face if the caliper is removed from the vehicle, until it stops. Repeat the process for both tappets.

tappet 13illustrator

14. After assembly check that the tappet boot seal assemblies are securely attached by pulling them lightly by hand. Check that the tappets are free to rotate slightly in each direction, taking care not to over-stress the tappet boots.

Note: LV225 & LA225 tappets (ref. MEI kit 5R0405) are identified by an annular groove on the outer face.

tappet 14a illustrator tappet 14b illustrator

15. If the caliper has been removed from the vehicle then replace as detailed in the GUIDE SLEEVE SEAL AND BUSH REPLACEMENT section. Refit the brake pads as described in the PAD REPLACEMENT section (this can be found on p.7-8 of the MEI Caliper Maintenance Guide).

Note: If the brake is removed from the vehicle then new axle mounting bolts should be used for re-installation.

Pad Replacement

Remove the wheel (referring to the vehicle manufacturer’s recommendations). Remove the pad retainer by removing the spring clip and washer then depressing the pad retainer to remove the pin. If necessary remove any pad wear warning indicator (PWWI) cable & clips (note the cable arrangement for fitting a new PWWI).

! Depending on the orientation of the caliper the brake pads could fall out when removing the pad retainer.

Maint Pad1 Maint Pad2 Maint Pad3

Remove the adjuster cap. Fully wind back the tappets, using a 10mm ring spanner or socket wrench, by turning the adjuster anti-clockwise as viewed from air chamber side.

! Never exceed a maximum torque of 25 Nm in either direction, and never use power tools.

Note: when turning anti-clockwise a noticeable clicking can be heard & felt.

Maint Pad4 Maint Pad5

Remove the worn brake pads and then check the caliper sliding. Note that the geometry of the LC225 brake requires that the caliper is pulled towards the outboard side first in order to remove the outboard pad and then pushed towards the inboard side to remove the inboard pad.

Check the rubber boots and replace if necessary. Clean the pad abutments of the carrier if required, taking care not to damage the rubber boots. Check the brake disc thickness and for signs of heavy grooving, cracking or corrosion.

Fully wind back the tappets using a 10mm ring spanner or socket wrench by turning the adjuster anti-clockwise as viewed from air chamber side and fit the new brake pads. Note that the geometry of the LC225 brake requires that the caliper is pushed towards the inboard side to fit the inboard pad first and then pulled towards the outboard side to fit the outboard pad.

Maint Pad6 Maint Pad7

! You must always replace the brake pads on both brakes across an axle.
! Ensure old brake pads are disposed of in accordance with local environmental regulations.

Turn the adjuster clockwise until the pads come into contact with the disc – do not exceed 25 Nm torque. Turn back the adjuster anti-clockwise 3 clicks and check the pad-to-disc running clearance – there should be free rotation of the disc. Refit the adjuster cap.

Maint Pad8 Maint Pad9 Maint Pad10

Locate the new pad retainer in the slot in the caliper and depress to enable the insertion of the pad retainer pin. Locate the washer over the pad retainer pin, then press the clip through the pad retainer pin to secure.

Maint Pad11 Maint Pad12 Maint Pad14


Note: it is recommended that pad retainer pin, where possible, is installed with pin head uppermost.


If applicable, fit a new pad wear warning indicator (PWWI) cable & clips in the same orientation as they were removed.

Maint Pad13b Maint Pad15

Replace the wheel in line with the vehicle manufacturer’s recommendations. Uncage the spring brake and apply the parking brake prior to removing the chocks from the vehicle. After releasing the parking brake, apply the brake 10 times then road test the vehicle to bed the pads and check the brake performance.

! Remember that there may be a lower performance during the bedding-in phase of the new brake pads.

Always ensure that the vehicle is securely chocked on level ground before releasing the parking brake. Cage the spring brake or use a minimum hold off pressure of 90 psi (6 bar).

Maint intro

LB195 Caliper Iveco   5B1400


 

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LB195 Caliper Iveco   5B1405


 

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LB195 Caliper BPW, SAF, Gigant, MBTA, DAF Bus, MAN   5B1500


 

Read more: 5B1500

LB195 Caliper BPW, SAF, Gigant, MBTA, DAF Bus, MAN   5B1505


 

Read more: 5B1505

LB195 Caliper MB Atego   5B1510


 

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LB195 Caliper MB Atego   5B1515


 

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LB195 Caliper MB Atego   5B1520


 

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LB195 Caliper MB Atego   5B1525


 

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LB195 Caliper MAN Truck   5B1530


 

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LB195 Caliper MAN Truck   5B1535


 

Read more: 5B1535

LB225 Caliper SAF, MBTA, Gigant, SAE, Iveco Truck   5C1100


 

Read more: 5C1100

LB225 Caliper SAF, MBTA, Gigant, SAE, Iveco Truck   5C1105


 

Read more: 5C1105

LB225 Caliper MERCEDES,MAN, ERF   5C1110


 

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LB225 Caliper MERCEDES,MAN, ERF   5C1115


 

Read more: 5C1115

LB225 Caliper MB Actros, Evobus DAF Bus   5C1120


 

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LB225 Caliper MB Actros, Evobus DAF Bus   5C1125


 

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LB225 Caliper Iveco   5C1150


 

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LB225 Caliper Iveco   5C1155


 

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LB225 Caliper BPW, SAF, Gigant, SAE, Scania, Neoplan   5C1400


 

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LB225 Caliper BPW, SAF, Gigant, SAE, Scania, Neoplan   5C1405


 

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LB225 Caliper DAF Truck, Foden   5C1410


 

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LB225 Caliper DAF Truck, Foden   5C1415


 

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LB225 Caliper Scania Truck & Bus, Neoplan   5C1420


 

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LB225 Caliper Scania Truck & Bus, Neoplan   5C1425


 

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LB225 Caliper MAN Truck   5C1430


 

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LB225 Caliper MAN Truck   5C1435


 

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LB225 Caliper DAF Truck   5C1440


 

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LB225 Caliper DAF Truck   5C1445


 

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LB225 Caliper Scania Truck   5C1450


 

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LB225 Caliper Scania Truck   5C1455


 

Read more: 5C1455

LB225 Caliper MB   5C1620
5C1620c

 

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LB225 Caliper MB   5C1625
5C1625c

 

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LB225 Caliper MAN TGA   5C1630
5C1630c

 

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LB225 Caliper MAN TGA   5C1635
5C1635c

 

Read more: 5C1635

LC225 Caliper BPW, SAF, SCB, MBTA   5C4400


 

Read more: 5C4400

LC225 Caliper BPW, SAF, SCB, MBTA   5C4405


 

Read more: 5C4405

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