BPW TSB 4309-228 Caliper Assembly Guide | All Key Points (Roller Bearing Position!)

Wed, 05 Nov 2025 12:04:21 +0000

⁣Bushing Installation Tool: https://www.cheeft.com/tr/prod....ucts/meritor/meritor

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⁣In this detailed training video, we demonstrate the professional overhaul and complete assembly process for the BPW TSB 4309-228 brake caliper, step-by-step. From disassembly, cleaning, and parts quality control to reassembly and final testing, every phase is explained to serve as a comprehensive resource for service centers and maintenance teams.

Discover the most critical "key points" in this video that impact the long-term performance of this caliper model.

⁣Key Topics and Critical Points Highlighted in the Video:
Parts Quality Control:

Lever & Bridge: Must be forging, not cast.

⁣Roller Bearing: Hardness must be over 45-50 Rockwell.

⁣Bushings: Must be bronze material, not brass.

⁣Rubber Boots: Must have heating protection to prevent melting and water ingress.

⁣Critical Assembly Steps:

⁣!!! THE MOST IMPORTANT STEP (Mechanism): After placing the mechanism in the housing, DO NOT LIFT IT UP. Lifting it will displace the roller bearing, causing the caliper to fail within 1-3 months.

⁣Roller Bearing Positioning: The bearing must be pressed into the lever perfectly flat and centered (using a hammer and screwdriver to align if needed).

⁣Lever Position: Ensure the lever's "nail" is correctly seated in its hole; incorrect positioning will cause the caliper to never work properly.

⁣Bolt Security (Loctite):

⁣Blue glue (Loctite) must be used on all bolts (especially mechanism and guide pins).

⁣Bolts loosening from vibration can cause the carrier to stick, misalign the brake chamber, and lead to catastrophic damage.

⁣Tightening Sequence: Always use a cross pattern when tightening the mechanism bolts.

⁣Testing and Adjustments:

⁣Mechanism Turn Count: Must be 3.25 (three and a quarter) turns, matching the original.

⁣Lever Test: The lever must not stick when released slowly (sticking causes heating).

⁣Final Adjustment: A 45-degree flexibility gap must be left in the adjuster at the end.

⁣Brake Chamber Warning: If the brake chamber pin is too long, it will cause a constant heating problem.