6
Brake Pads and Caliper
HYDRAULIC BRAKE AND PARK BRAKE
SYSTEMS
WARNING
• To reduce the possibility of diminished brake performance or failure, never use petroleum-based
lubricants on brake system components, and ensure lubricant does not contact friction surfaces of
brake pads or rotors.
2.
Secure caliper assembly to steering upright with two, new socket-head bolts (5). Tighten bolts to 37 lb-ft (50 N·m).
3.
Secure the brake hose to the caliper with banjo bolt (3) and new copper washers (4). Tighten to 13 lb-ft (18
N·m).
See following CAUTION.
CAUTION
• The banjo bolts are metric. Use only metric thread replacements.
4.
Fill the reservoir of the master cylinder and bleed the hydraulic system.
See Bleeding the Hydraulic Brake
System on page 6-18. See following WARNING.
WARNING
• Ensure hydraulic hoses cannot contact any moving parts that will cause wear and damage.
5.
Repeat procedure for the opposite brake if necessary.
6.
Install the tire and wheel. Finger-tighten the lug nuts.
7.
Lower the vehicle and use a crisscross pattern to tighten the lug nuts to 85 ft-lb (115 N·m).
8.
Inspect the brake system.
See Brake System Inspection on page 6-1.
REAR BRAKE PAD AND CALIPER REMOVAL
WARNING
• Due to piston size, 2-passenger and 4-passenger vehicles have different rear calipers. Be careful not
to interchange parts.
• If at any point in this procedure the hydraulic system is opened, the brakes must be bled after the
correct reinstallation of the brake components. Failure to bleed the brakes could result in decreased
braking performance due to air being trapped in the hydraulic system. Use only DOT 5 brake fluid. See
Bleeding the Hydraulic Brake System on page 6-18.
• Prior to servicing hydraulic brakes, thoroughly clean the vehicle, paying particular attention to areas
immediately surrounding hydraulic connections, to prevent dirt or debris from entering system.
CAUTION
• Do not pump the brake pedal without brake fluid in the master cylinder and reservoir.
• Worn or damaged brake discs cannot be machined to refinish them. Replace as necessary.
1.
Lift and support the rear or entire vehicle and remove the wheel(s).
See Lifting The Vehicle, Section 3, Page 3-7.
2.
If replacing pads only, skip to step 6.
3.
If replacing caliper, remove the banjo bolt (5) and copper washers (4) holding brake hose to caliper. Discard the
copper washers
See following NOTE.
Page 6-10
2016 Carryall 1500/1700 and XRT 1550 Maintenance and Service Manual
Summary of Contents for Carryall 1500 2016
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