Abstract: A disc brake assembly arranged to be mounted over a rotor. The disc brake assembly includes first and second brake pads, a caliper having an opening for receiving the first and second brake pads, and a spring member for retaining the pads within the caliper. The spring member has a pad alignment feature arranged to prevent the spring member from being properly assembled on the caliper when one or more of the brake pads is inserted with its friction material facing away from a rotor receiving region of the caliper.

Abstract: A disc brake and a brake pad assembly. The brake pad assembly may have a brake pad and a retainer clip. The brake pad may have a volume of friction material that may include a friction face, a support face, first and second circumferential end faces. The retainer clip may be arranged to engage a bearing surface of the brake pad.

Abstract: A disc brake having an actuation mechanism, a disc brake rotor, first and second brake pad mounting structures, and first and second brake pads. The first and second mounting structures may have formations that affect fitting of the first and second pads.

Abstract: An adjuster assembly for manually adjusting the position of a brake pad relative to a brake rotor of a disc brake, the assembly comprising: a continuous wear sensor; and a manual rewind apparatus to manually reset the position of the brake pad when replacement thereof is required; the manual rewind apparatus comprising a shaft arranged to extend into a housing of the disc brake; wherein the continuous wear sensor is arranged to be located within the housing of the disc brake and is located proximate to the shaft.

Abstract: A disc brake having an actuation mechanism, a disc brake rotor, first and second brake pad mounting structures, and first and second brake pads. The first and second mounting structures may have formations that affect fitting of the first and second pads.

Abstract: A force transmission device, tappet, and method of manufacture. The tappet may include a shaft portion for transmission of a thrust loading from an actuating member to a piston of a disc brake and a gear portion for transmission of rotary motion to the shaft. The gear portion may be formed as a separate piece from the shaft portion.

Abstract: A method of operating a mechanically operated brake having an electric motor for operating an adjuster mechanism that may include the steps of: a) providing a brake rotor and friction material for selective engagement with the brake rotor, b) providing a target running clearance between the brake rotor and the friction material, c) applying the brake by forcing the friction material into engagement with the brake rotor, d) determining that the friction material is set in a compressed condition, e) releasing the brake, f) operating the electric motor to operate the adjuster mechanism to adjust the instantaneous running clearance towards the target running clearance, g) then applying the brake.

Abstract: A force transmission device for a disc brake operable to move a friction element of the brake into engagement with a rotary brake disc along a first axis in response to a loading from an actuating member, the device comprising: a guide member having a generally cylindrical guide form; a piston comprising a complementary generally cylindrical outer sliding surface slideable within the guide member, wherein; an anti-rotation formation is provided between the guide member and the piston, the formation comprising a recess extending generally parallel to the first axis and a complementary projection.

Abstract: A brake having an adjustable tappet for applying a brake force to a brake pad, a tappet having a rotating part in threaded engagement with a non-rotating part, the rotating part including a tappet gear, an adjuster mechanism for selectable rotating the tappet gear, the adjuster mechanism having a clutch with a driving clutch plate in frictional engagement with a driven clutch plate, the driven clutch plate having external teeth in direct meshing engagement with the tappet gear.

Abstract: A carrier and mount assembly for a heavy vehicle disc brake. The assembly includes a carrier having a first location formation formed therein, a mount having a second location formation formed therein, wherein the second location formation is aligned with the first location formation, and wherein the carrier is mounted to the mount via two or more fasteners that extend in a direction substantially parallel to a direction of insertion or removal of a friction element into or from the carrier. There is also a locator positioned in the first and second location formations to enable the carrier and mount to be assembled in the correct position, wherein the locator is at least a close fit to the first and second location formations.

Abstract: A method of replacement of replaceable components of a vehicle braking system are described, along with methods of controlling such replacement by preventing the or permitting removal of replaceable components of a braking system, in response to comparison of codes associated with current and replacement parts of the braking system. A related braking system and controller are also disclosed. The methods and related products can be used for ensuring the replacement of braking components with correctly specified replacement parts.

Abstract: A method of determining if any usable life remains in a brake component of a brake, the method comprising the steps of using a processor to determine a total number of brake events, and using a processor to determine from the total number of brake events if any usable life remains in the brake component.

Abstract: A brake carrier for a heavy vehicle disc brake includes an actuating side carrier portion including a support for an actuating side brake pad having a first material having a first property. The brake carrier also includes a separate reaction side carrier portion having a support for a reaction side brake pad for securement to the actuating side carrier portion. The actuating side carrier portion includes a first material having a first property, and the reaction side carrier portion includes a second material having a second property, wherein the second property differs from the first property.

Abstract: A vehicle brake assembly including a brake caliper defining a caliper housing and defining a plane of rotation of a brake disc, the housing having an opening facing the plane of rotation of a brake disc, a cover plate for closing the opening and an actuator assembly at least partially mounted in the housing, wherein the actuator assembly includes at least one piston for moving a friction element into contact with a brake disc, an adjuster mechanism for adjusting the effective length of the at least one piston, the adjuster mechanism including an adjuster shaft, the adjuster shaft being fixed to the cover plate by a spring clip arrangement.

Abstract: An adjuster system for adjusting the position of a brake pad relative to a brake disc so as to maintain a suitable running clearance between the pad and disc in a disc brake. The system comprises a manual rewind apparatus to reset the position of the brake pad when replacement thereof is required. The manual rewind apparatus has a transmission path extending from a rewind tool engaging portion to a brake pad engaging portion of the system. The manual rewind apparatus is configured such that when a rewind torque above a pre-determined torque is applied to the transmission path by a rewind tool no damage is caused to components along the transmission path.

Abstract: A disc brake assembly includes a brake pad having a first pad abutment spaced from a second pad abutment and a third pad abutment positioned between the first pad abutment and the second pad abutment. An actuator is operable to apply a force to the brake pad to apply the brake. The disc brake assembly has a first reaction abutment facing the first pad abutment, a second reaction abutment facing the second pad abutment, and a third reaction abutment facing the third pad abutment. The first, second and third pad abutments are operable to transfer brake pad drag torque to the first, second and third reaction abutments respectively. The disc brake is configured such that under no load conditions with the third pad abutment engaging the third reaction abutment, the first pad abutment is spaced from the first reaction abutment.

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 disc brake includes a brake disc, a sliding caliper, a single piston, and a brake pad carrier comprising a leading part and a trailing part. The brake pad carrier includes mounting features for securing the brake pad carrier to an associated structure of a vehicle. The mounting features define a mounting side and a non-mounting side of the brake. A mounting side brake pad comprises mounting side friction material and a non-mounting side brake pad comprising non-mounting side friction material. The center of pressure of the non-mounting side friction material is circumferentially aligned with the piston and the center of pressure of the mounting side friction material is offset in relation to the piston towards the leading part of the brake pad carrier.

Abstract: A brake adjuster mechanism including an input shaft, a one-way clutch, and a torque limiting clutch. The input shaft is coupled to an input element of the torque limiting clutch. The one-way clutch is coupled to the torque limiting clutch. The torque limiting clutch further includes an output element and a coupling portion, with the coupling portion including a projection for selectively rotationally coupling the input element and the output element. One of the input element and output element includes a first recess circumferentially spaced from a second recess. The projection is selectively biased into the first recess and the second recess. The input element is frictionally coupled by a friction device to the output element to resist rotation of the input element relative to the output element.

Abstract: A vehicle brake assembly including a brake caliper defining a caliper housing and defining a plane of rotation of a brake disc, the housing having an opening facing the plane of rotation of a brake disc, a cover plate for closing the opening and an actuator assembly at least partially mounted in the housing, wherein the actuator assembly includes at least one piston for moving a friction element into contact with a brake disc, an adjuster mechanism for adjusting the effective length of the at least one piston, the adjuster mechanism including an adjuster shaft, the adjuster shaft being fixed to the cover plate by a spring clip arrangement.