Avid Technology BBDB User manual

BBAALLLLBBEEAARRIINNGGDDIISSCCBBRRAAKKEE
SSEERRVVIICCEEGGUUIIDDEE

TYPE F Ball Bearing Disc Brake
TYPE N Ball Bearing Disc Brake
Exploded Views
Outboard Adjuster
Knob
Torque Arm
Fixing Nut
Detent
Washer
Flat
Washer
Torque Arm
Outer Caliper
Body Seal
Spring
Hex Hole
Washer
Spring Adjuster
Plate
Lockring
Retainer
Lockring
Fixed Cam
Ball-Bearings
Drive Cam
Foot Screw
Outboard
Pressure Foot
Inboard
Pressure Foot
Inner Body Seal Lower Cable
Seal Boot
Upper Cable
Seal Boot
Cable Housing Ferrule
Spring Adjuster
Screw
Inboard Adjuster
Knob
Cable Anchor
Plate
Cable Anchor
Bolt
Fixed Cam
Ball-Bearings
Drive Cam
Foot Screw
Outboard
Pressure Foot
Inboard
Pressure Foot
Inner Body Seal
Lower Cable
Seal Boot
Upper Cable
Seal Boot
Inboard Adjuster
Knob
Outboard Adjuster
Knob
Torque Arm
Fixing Nut
Detent
Washer
Flat
Washer
Torque Arm
Outer Caliper
Body Seal Spring
Hex Hole
Washer
Lockring
Retainer
Lockring
Cable Anchor
Plate
Cable Anchor
Bolt
Spring
Adjuster
Spring
Adjuster Screw
Lower Truss
Bolt
Upper Truss
Bolt
Upper Truss
Bolt
Lower Truss
Bolt
Aug 03 - Avid, LLC

TABLE OF CONTENTS
SECTION I - Introduction page 2-3
SECTION II - Disassembly page 4-8
SECTION III - Cleaning & Inspection page 9-10
SECTION IV - Assembly page 11-21
1

Introduction
2
TYPE F calipers have
a red Avid logo
badge here
TYPE N calipers have
a red and white Avid
logo decal on the back
of the body.
The most common problem that doesn’t require disassembly:
A common BBDB call we get is about a caliper with the outboard pressure foot dislodged. If the outboard adjustment
knob is turned too far clockwise without the rotor in the caliper (wheel off or caliper removed), the outboard pressure foot
can be pushed out of the drive cam and float free in the caliper body. The brake is not broken and it doesn’t need to be
disassembled to replace the pressure foot.
To replace the pressure foot, turn the outboard adjuster knob counter clockwise until it stops. If the knob doesn’t stop,
then the footscrew (you can see the end of the footscrew in the center of the knob) has become disengaged from the
knob, and possibly from the threads inside the drive cam. In this case, remove the knob, then use some small needle-
nosed pliers or a Schrader-valve tool to turn the foot screw all the way back out until it stops. Once this is accomplished
the pressure foot can be replaced. Relocate the pressure foot into the bore, then give it a firm push in the center. It will
“click” back into place.
If you removed the outer knob, replace it, and you’re done!
WARNING
Brakes are a safety-critical item on a bicycle. Improper re-assembly of this or any other brake component can result in
loss of control or an accident, which could lead to a serious injury or death. The work detailed in this guide is
intended for and should only be performed by professional bike mechanics.
This overhaul guide covers the TYPE F and TYPE N models of Avid’s Ball Bearing Disc Brake. While these brakes are
very similar in design, there are some differences in assembly and internal parts. As you follow the guide, any steps that
are the same will only contain pictures for the TYPE N brake. One easy way to tell if you are working on a TYPE F or
TYPE N caliper is this:

About the Truss Bolts:
Avid’s Ball Bearing Disc Brake calipers are a one piece body that incorporate 2 Truss Bolts for strength. These bolts
have tamper-proof heads, and are not be removed for any reason.
Truss Bolts
These bolts should not be removed for any
reason! If you have the proper tool, you can
check that the torque is 50-55 In. Lbs.
Otherwise, don’t touch them!
About the Spreader Clip:
Avid’s TYPE N Ball Bearing Disc Brakes utilize a pad spreader clip that sits between the pads (instead of magnets) to
keep them retracted. The original spreader clip had two ears with loops that protruded from the caliper, but we have
since changed the design. The new clip works exactly the same way, but has nothing sticking out of the caliper.
Old design with
loops
New design
without loops
Torque Specs:
Recommended Grease:
Use a grease with a minimum temperature rating of 400 degrees Farenheit such as Tri-Flowtm High Performance
Synthetic Grease with Teflon
®
or Pro-Gold EPX Cycle Grease.
Lockring 140-150 In. Lbs
Torque Arm Fixing Nut 55-60 In. Lbs
Truss Bolts 50-55 In. Lbs
3
Tools needed:
3/8 drive ratchet, Avid MDT-1 lockring tool, 11mm socket, 11mm box-end wrench, 1.5mm and 5mm hex wrenches,
flat-blade screwdriver, torque wrench (50-150 In. Lbs range), small needle-nose pliers or a Schrader-valve tool.
Shop supplies:
Degreaser or solvent, mild soap, grease (see below for grease recommendations), a small brush, and thread-lock such
as Loctite 272.

TYPE F TYPE N
STEP 1: PREPARE FOR DISASSEMBLY
Remove the cable anchor bolt and plate, then pull
the cable housing and inner wire free of the
caliper. Remove the boots, and, if working on a
TYPE F caliper, the separate housing ferrule in
the cable stop. Also on TYPE F calipers, use a
2.5mm hex wrench to completely remove the
spring tension adjustment screw.
STEP 2: REMOVE THE OUTBOARD
KNOB
A.Turn the outboard pad knob counter-clockwise
until it stops, then back in clockwise 3 full turns to
recess the footscrew in the knob.
NOTE:
Turning the outboard knob more than 3 full
turns can dislodge the outer pressure foot
from the drive cam. If this happens, proceed
with removing the knob. After step 2-C, the
pressure foot can be pressed back into place.
C. Turn the now exposed footscrew back out
(counter-clockwise) until it stops.
B. Remove the knob with a small flat-blade
screwdriver, being careful not to mar the surface
of the torque arm.
Disassembly 4

STEP 3: INSTALL PAD SPACER
Turn out the inboard adjuster (counter-clockwise)
until there is enough clearance between the pads
for a 2mm pad spacer. Insert the spacer, then
turn in the inboard knob (clockwise) until it stops.
Check the torque arm for movement. If it moves,
turn the footscrew clockwise until it is secure.
NOTE:
If you need to fabricate a pad spacer, be sure
to use cardboard or something similar that
will not damage the surface of the friction
material.
TYPE F TYPE N
STEP 4: REMOVE TORQUE ARM
A. Place your thumb over the spring loaded
torque arm as shown and hold securely.
B. Remove the torque arm fixing nut using an
11mm wrench.
C. While continuing to hold the torque arm,
remove the indexed washer and flat washer.
5

TYPE N
TYPE F
D. TYPE F - Remove the torque arm, outer body
seal, and spring together, then remove the
hex-hole washer.
E. TYPE F - Tip the bike to allow the spring
adjuster plate and lockring retainer to fall into
your hand.
D. TYPE N - Remove the torque arm, spring
adjuster, outer body seal, and spring together,
then remove the hex-hole washer.
E. TYPE N - Tip the bike and allow the lockring
retainer to fall into your hand.
6

TYPE N
TYPE F
STEP 7: REMOVE CAMS
Pull out the cam/outboard pressure foot assem-
bly. Once this assembly is out, remove the pads
and pad spacer from the caliper.
STEP 8: REMOVE INBOARD ADJUSTER
KNOB
Using a small flat blade screwdriver, remove the
inboard adjuster knob.
STEP 5: FREE LOCKRING
Using the Avid MDT-1 Lockring Tool and a 3/8
drive ratchet, break the lockring free. Now
remove the caliper from the bike.
STEP 6: REMOVE LOCKRING
Using the MDT-1 by hand, completely remove the
lockring.
7

STEP 9: REMOVE INBOARD PRESSURE
FOOT
Turn the inboard pressure foot clockwise until it is
free, then remove it through the main body bore.
STEP 10. REMOVE INNER BODY SEAL
There is one split in this seal for installation and
removal purposes. Engage the seal at the split
with an x-acto knife or other small sharp tool and
carefully remove it.
STEP 11: CAM DISASSEMBLY
A. Lift the fixed cam off of the drive cam, being
careful not to lose the 3 ball bearings.
B. Use small needle-nose pliers or a Schrader
valve core tool to turn the foot screw clockwise
until the outboard pressure foot is driven out of
the drive cam. Continue turning the foot screw
until it is completely unthreaded from the drive
cam.
TYPE F TYPE N
Split
8

Cleaning&Inspection
STEP 1: CLEANING
Clean all metal parts in solvent, including the
cable anchor bolt and plate, and for TYPE F
brakes, the separate cable housing ferrule. Clean
the cable seal boots, outer caliper body seal, and
inner body seal in mild soap and water.
Rinse and dry all parts completely.
STEP 2: CALIPER BODY INSPECTION
Inspect the caliper body for any damage, paying
special attention to all threaded surfaces and the
pad retainer clip in the top of the caliper body.
Lockring
Threads
Inner Pressure
Foot Threads
Pad Retainer
Clip
9

STEP 3: SMALL PART INSPECTION
Inspect the small parts as follows:
-check ball bearings and cam ramps for
excessive wear.
NOTE: It is normal to see ball tracks in the
cam ramps.
-check the threads of the drive cam, foot
screw, lockring, inner pressure foot,
cable anchor bolt, and torque arm fixing
nut for damage.
-check the spring for any signs of
damage.
-on TYPE F calipers, make sure the
pressure foot magnets are present and
working.
-check the inner body seal, outer body
seal, and cable seal boots for nicks,
tears, or cracking.
10

STEP 1: INSTALL INNER BODY SEAL
Orient the inner body seal with the groove facing
down, then insert it into the main body bore.
Locate the seal into its recess and seat it
completely with your finger.
Assembly
STEP 2: GREASE THE BODY
Very lightly grease the entire body bore,
including the lockring threads, the inner pressure
foot threads, and the inner knob detents.
STEP 3: INSTALL INNER PRESSURE
FOOT
Drop the inner pressure foot in through the main
body bore, then thread it in counter-clockwise
until it bottoms out.
TYPE F TYPE N
STEP 4: INSTALL INNER KNOB
Install the inboard adjuster knob by lining up the
rectangular tab on the back of the pressure foot
with the hole in the knob, then pressing it on firmly.
11
Groove
Seal Recess

STEP 5. RE-MOUNT CALIPER
Re-mount the caliper onto the bike.
TYPE F TYPE N
STEP 6: INSTALL PADS & SPACER
Install the pads and spacer into the caliper and
turn the inboard adjuster knob clockwise to lock
into place.
STEP 7. GREASE CAM PARTS
Grease very lightly the following parts in
preparation for assembly:
-footscrew threads
-tip of stem-end on outer pressure foot
-ramps of drive cam and fixed cam
Grease here
Grease here
Grease here
Grease here
12

STEP 9. INSTALL OUTBOARD PRES-
SURE FOOT
Engage the stem-end of the outer pressure foot
into the hole in the end of the drive cam and
install by firmly pressing it straight in.
STEP 10: ASSEMBLE THE CAMS
Place the ball-bearings into the ramps of the drive
cam, then install the fixed cam over the shaft of
the drive cam. Rotate the cams against each
other to ensure the ball-bearings are seated
properly in both sets of ramps.
STEP 8. INSTALL FOOT SCREW
Using small needle-nose pliers or a Schrader
valve tool, thread the footscrew into the drive cam
completely, but do not tighten.
TYPE F TYPE N 13

STEP 11: INSTALL CAM ASSEMBLY
A. Hold the cam assembly by the drive cam while
keeping pressure on the fixed cam with your
thumb and index finger. This serves two
functions:
1. It keeps the ball-bearings properly
positioned in their ramps.
2. It ensures the drive cam is not pushed
past the inner body seal. If the drive
cam is pushed past the inner body
seal and then pulled back, the edge of
the inner body seal rolls back. If this
occurs, the seal must be replaced.
B. Align the tab on the fixed cam to the
corresponding groove in the caliper body. Install
the assembly, being sure to press it in by the
fixed cam, not the shaft of the drive cam. Align this tab
with the groove
in the body
STEP 12: INSTALL LOCKRING
Install the lockring by hand with the MDT-1.
STEP 13: TORQUE LOCKRING
Torque the lockring with the MDT-1 to 140-150 In.
Lbs.
TYPE F TYPE N 14

TYPE F TYPE N
STEP 14: INSTALL LOCKRING RETAINER
TYPE F - Install the lockring retainer, aligning the
cut-out in the retainer with the tab on the fixed
cam.
TYPE N - Install the lockring retainer, aligning the
tab on the retainer with the cut-out in the fixed
cam.
STEP 15 (TYPE F ONLY): INSTALL
SPRING ADJUSTER PLATE
Install the spring adjuster plate, rotating it to the
lowest spring tension setting. This position will
make it easier to install the torque arm later.
STEP 16 (TYPE F ONLY): INSTALL
SPRING ADJUSTER SCREW
Install the spring adjuster screw, turning it in just
far enough to engage the spring adjuster plate.
15

TYPE F TYPE N
STEP 17: INSTALL HEX-HOLE WASHER
Place the hex-hole washer over the drive cam
shaft, engaging the flats on the shaft.
STEP 18: APPLY THREAD-LOCK
Apply a high-strength thread-lock such as Loctite
272 to the drive cam threads. Be careful not to
allow any thread-lock to enter the area around
the footscrew.
STEP 19: INSTALL SPRING
TYPE F - Install the spring with the short spring
tab engaging the hole of the spring adjuster plate.
TYPE N - Install the spring with the long spring
tab engaging the hole in the fixed cam.
16

TYPE F TYPE N
STEP 20: INSTALL OUTER SEAL
Place the outer body seal on the spring, engaging
the spring tab into the hole in the boot.
STEP 21 (TYPE N ONLY): INSTALL
SPRING ADJUSTER
Turn the spring adjuster screw counter-clockwise
until the bottom is flush with the bottom of the
adjuster. Then install the spring adjuster on top of
the outer body seal, engaging the spring tab into
the hole in the spring adjuster.
STEP 22: PART & TOOL ORIENTATION
At this time, take a moment to arrange and orient
the flat washer, detent washer, and torque arm
fixing nut for installation. If they are ready to go,
they will be much easier to install while holding
the spring-loaded torque arm in place.
After the torque arm is on, the installation order
will be as stated above (flat washer, then detent
washer, then torque arm fixing nut.)
Of these pieces, the detent washer is the only
one with a “right-side up” and “up-side down.” If
you look at the profile, there is a sharp edge and
a rounded edge. The rounded edge goes up.
This allows the outboard adjustment knob to be
installed fairly easily as it is pressed on over the
rounded outer edge, while the sharp inner edge
keeps it firmly in place. Sharp
Edge
Rounded
Edge
17

STEP 23: INSTALL TORQUE ARM
TYPE F - Install the torque arm by first engaging
the spring tab into the hole on the back side of
the arm, then pressing the arm onto the flats of
the drive cam shaft. Make sure the arm is fully
seated, and hold it firmly in place with your
thumb.
NOTE:
Proper orientation will place the top of the
torque arm just below the bottom truss bolt.
TYPE F TYPE N
TYPE N - Install the torque arm, aligning the
spring adjuster tab and screw with the relieved
area on the back of the torque arm. When
engaged correctly, the spring adjuster screw will
be driven against the shelf on the back of the
torque arm. Press the torque arm onto the flats of
the drive cam shaft. Make sure the arm is fully
seated and hold firmly with your thumb.
NOTE:
Proper orientation on a 2002 MTB caliper will
place the top of the torque arm just below the
bottom truss bolt. If working on a ROAD
caliper, the torque arm will be directly in front
of the truss bolt.
18
MTB Caliper Road Caliper