WHEEL BRAKE ASSEMBLIES
Brake Cluster Removal and Installation
6
BRAKE CLUSTER REMOVAL AND INSTALLATION
See General Warnings on page 1-1. See also Asbestos Dust Warning on page 6-1.
BRAKE CLUSTER REMOVAL
1.
Disconnect the battery cables and discharge the controller as instructed.
See WARNINGS “To avoid
unintentionally starting...” and “After disconnecting the batteries, wait 90 seconds...” in General
Warnings on page 1-1.
2.
Place chocks at the front wheels and loosen the lug nuts on the rear wheels. Lift the rear of the vehicle with a
chain hoist or floor jack. Place jack stands under the axle tubes to support the vehicle.
See WARNING “Lift
only one end...” in General Warnings on page 1-1.
3.
Gain access to the pedal group by removing the floor mat and access panel.
See Pedal Group Removal
on page 5-1.
4.
Loosen the two jam nuts (1 and 3) on either side of turnbuckle (2)
(Figure 6-1, Page 6-2)
. Note that the forward
jam nut (1) is a left-hand thread. Thread each nut approximately 1/2 inch (12.7 mm) away from the turnbuckle.
5.
Loosen turnbuckle (2) to release tension on the equalizer bracket (4) that pulls on the heads of the brake cables.
6.
Remove lug nuts and rear wheels and then the brake drums.
NOTE:
When servicing vehicles with self-adjusting brakes with badly worn brake shoes and when the drums cannot
be removed by normal methods, perform Step 7 of
Brake Shoe Removal on page 6-1
, then continue
with this procedure.
Although step 7 below allows easier access to the brake shoes, it is not imperative to do so in order to
remove the brake shoes.
7.
Remove the axle.
7.1. Using 90° snap ring pliers (CCI P/N 1012560), remove the axle retaining ring (1)
(Figure 6-3, Page 6-2)
.
7.2. Pull the axle shaft (2) from the axle tube
(Figure 6-3, Page 6-2)
.
8.
Remove bow tie locking pin (13) and clevis pin (12) from brake cable
(Figure 6-4, Page 6-3)
.
9.
Remove four bolts (11) and lock nuts (10) that mount the brake assembly to the transaxle
(Figure 6-4, Page 6-3)
.
10. Remove brake assembly from transaxle.
BRAKE CLUSTER INSTALLATION
1.
Install in reverse order of disassembly. Use new bow tie locking pins when installing brake cables.
CAUTION
• Before installing axle shaft, clean any residual oil from the exposed end of the axle tube and from
the oil seal area.
2.
Be sure bolts (11) (CCI P/N 1014153) and new lock nuts (10) (CCI P/N 1013924) are used to mount the brake
assembly
(Figure 6-4, Page 6-3)
.
3.
Tighten nuts to 17 ft-lb (23.0 N·m). If torquing the bolt heads, torque to 30 ft-lb (40.6 N·m).
4.
Install the rear axle onto the transaxle.
See following NOTE.
2009 Electric Precedent Maintenance and Service Manual
Page 6-11
