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

Regular brake inspection is an important part of vehicle maintenance and should take place every 3 months.

These check frequencies are a minimum and, depending on the vehicle application, a more frequent check may be necessary. Refer also to vehicle manufacturer’s instructions with regard to check frequencies and service intervals for brake calipers, brake pads, brake discs and air chambers.


Brake Pad Wear

A visual assessment of brake pad wear should be made – independent of any wear indicator fitted to the vehicle. There are two methods of carrying out a quick and simple assessment of the approximate pad life remaining without removing the wheel.

Method 1

Compare the position of the caliper marking X with respect to the carrier marking Y. If the positions of X and Y are similar to those shown in the right hand diagram then the brake pad and the brake disc thickness should be checked with the wheel removed.

Maint Reg BP

Method 2

Compare the position of the caliper with respect to the end of the short guide sleeve, where applicable. If dimension Z is less than 1 mm then the brake pad and the brake disc thickness should be checked with
the wheel removed.

Maint Reg BP2


If the visual assessment indicates the pads are approaching their maximum wear allowance then a full check with wheel removed should be made. Brake pads should be replaced when the friction lining C has worn to a thickness of 2.0 mm or less.


You must always replace the brake pads on both brakes across an axle.

Maint Reg BP3


Visually inspect the brake for damage or corrosion, paying particular attention to the guide sleeve boots and tappet boots. Check that the adjuster cap is correctly fitted. If in doubt follow the additional checks in this maintenance procedure and if necessary replace any damaged parts using the relevant MEI service kit.

Guide Sleeve Boots

Maint Reg Cor1 Maint Reg Cor2


Tappet Boots

Maint Reg Cor3

Brake Disc

Measure the thickness of the brake disc at its thinnest section – brake discs should be replaced when the overall thickness E has worn to 37.0 mm or below.

! Be aware of possible burrs or lips at the outer edge when checking the disc thickness.

Note: The brake discs should be checked according to the vehicle manufacturer’s specification, looking for signs of heavy grooving, cracking or corrosion.

Maint Reg BD1 Maint Reg BD2

If disc thickness E is less than 39 mm it is recommended that the disc should be replaced when the brake pads are changed.

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