Abstract: A retaining formation defined on a brake lever of an air disc brake includes a push fit/snap fit connection for releasably securing a push rod to a brake lever. The retaining formation can include a pinned connection and a ball and socket joint, and a main axis of the pinned connection is coincident with a center of rotation of the ball and socket joint. The retaining formation can include a concave formation on one of the push rod and the brake lever and a corresponding convex formation on the other of the push rod and the brake lever. The concave formation at least partially surrounds the convex formation to prevent axial separation of the push rod and the brake lever. A method of assembling a brake subassembly includes the steps of assembling a push rod and a brake lever including a retaining formation such that at least a portion of the retaining formation deforms during assembly and resiles when the push rod is assembled to the brake lever to provide a snap fit connection therebetween.

Abstract: A co-axial wear adjuster and wear sensor for a brake caliper includes a sleeve having an external tooth form engageable with a toothed adjustment wheel of a brake tappet. The sleeve rotates with the tappet and is threaded to engage a relatively non-rotatable, but axially movable, bolt. A wear sensor is partly within the sleeve and has a plunger operably engaged with the bolt. The bolt may be tubular to carry a screw-threaded head whereby a position of the plunger may be set.

Abstract: An actuating lever of a brake caliper of a vehicle includes a cam surface operable against a single tappet and reacting against a caliper bridge. The actuating lever includes a wear adjuster arm which exerts a turning moment on the actuating lever. The turning moment is resisted by a small stub axle pivotable in a plain bearing of the brake caliper.

Abstract: A retaining formation defined on a brake lever of an air disc brake includes a push fit/snap fit connection for releasably securing a push rod to a brake lever. The retaining formation can include a pinned connection and a ball and socket joint, and a main axis of the pinned connection is coincident with a center of rotation of the ball and socket joint. The retaining formation can include a concave formation on one of the push rod and the brake lever and a corresponding convex formation on the other of the push rod and the brake lever. The concave formation at least partially surrounds the convex formation to prevent axial separation of the push rod and the brake lever. A method of assembling a brake subassembly includes the steps of assembling a push rod and a brake lever including a retaining formation such that at least a portion of the retaining formation deforms during assembly and resiles when the push rod is assembled to the brake lever to provide a snap fit connection therebetween.

Abstract: An actuating lever of a brake caliper of a vehicle includes a cam surface operable against a single tappet and reacting against a caliper bridge. The actuating lever includes a wear adjuster arm which exerts a turning moment on the actuating lever. The turning moment is resisted by a small stub axle pivotable in a plain bearing of the brake caliper.

Abstract: A co-axial wear adjuster and wear sensor for a brake caliper includes a sleeve having an external tooth form engageable with a toothed adjustment wheel of a brake tappet. The sleeve rotates with the tappet and is threaded to engage a relatively non-rotatable, but axially movable, bolt. A wear sensor is partly within the sleeve and has a plunger operably engaged with the bolt. The bolt may be tubular to carry a screw-threaded head whereby a position of the plunger may be set.

Abstract: A lever assembly for a vehicle brake includes an operating shaft having a lever aperture, a lever engageable with the lever aperture and a retainer pin insertable into the lever assembly to retain the lever in the lever aperture.