BRAKES
Page D-9
Repair and Service Manual
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings
WHEEL BRAKE ASSEMBLY
REPLACEMENT
Tool List
Qty. Required
Socket, 3/4", 1/2" drive................................................ 1
Ratchet, 1/2" drive....................................................... 1
Wheel chocks.............................................................. 4
Hydraulic floor jack...................................................... 1
Jack stands ................................................................. 2
Socket, 1/4" hex bit, 3/8" drive .................................... 1
Ratchet, 3/8" drive....................................................... 1
Socket, 1/2", 3/8" drive................................................ 1
Socket, 9/16", 3/8" drive.............................................. 1
Needle nose pliers ...................................................... 1
Torque wrench, 3/8" drive, in. lbs. ............................... 1
Torque wrench, 3/8" drive, ft. lbs. ................................ 1
If one wheel brake
assembly requires
r e p l a c e m e n t , t h e
second must also be replaced.
Wear a dust mask and eye protection when-
ever working on wheel brakes. Do not use
pressurized air to blow dust from brake
assemblies.
Be sure that the parking brake is released.
Loosen rear wheel lug nuts and lift rear of vehicle per
Section B.
Remove wheel and drum. See ‘BRAKE DRUM
REMOVAL AND INSTALLATION’ on page D-5.
Loosen the four allen head bolts and lock nuts securing
the wheel brake backing plate to the flange on the axle
tube (Ref Fig. 5 on page D-6). Remove banjo bolt to
detach brake line from wheel cylinder. Remove the four
allen head bolts and lock nuts and discard.
Remove the clevis pin securing the park brake cable to
the wheel brake lever.
Installation is the reverse of removal. Connect the brake
cable to the wheel brake lever with the clevis pin installed
from the top down and a new cotter pin. Loosely install
wheel brake assembly to axle tube flange using new
hardware. Attach brake line to wheel cylinder using new
copper gaskets and tighten banjo bolt to 124 - 177 in. lbs.
(14 - 20 Nm) torque. Tighten allen head bolts and lock
nuts to 23 - 27 ft. lbs. (31 - 37 Nm) torque.
BLEEDING AND FLUSHING
Tool List
Qty. Required
Shop towels............................................................. A/R
Hose ........................................................................ A/R
Clean container ........................................................... 1
Brake fluid, DOT 3................................................... A/R
Wrench, 1/4" box end .................................................. 1
Crowfoot wrench, 1/4", 3/8" drive ................................ 1
Torque wrench, 3/8" drive, in. lbs. ............................... 1
Bleeding
The brake hydraulic system must be free of air to func-
tion properly. Any air in the system is compressed when
pressure is applied, and the result is a springy, spongy
brake pedal.
Air may enter the system if any of the hydraulic parts are
disconnected or if the brakes are operated with the mas-
ter cylinder fluid very low.
The process of removing any air that may be trapped in
the hydraulic system is known as bleeding the brakes.
Bleeding requires the use of the brake pedal and master
cylinder as a hydraulic pump to expel air and brake fluid
from the system when a bleeder screw is opened.
Bleed the complete hydraulic system at both wheels if …
•
Primary brake line was disconnected from the
flexible brake hose
•
Air was introduced into the system through low
fluid level in master cylinder reservoir.
If a line or hose was disconnected at any fitting located
between the master cylinder and the wheel cylinders,
then all wheel cylinders served by the disconnected line
or hose must be bled.
Bleeding Sequence
Bleed at each wheel cylinder in succession, beginning
with the passenger side wheel, which is farthest from the
master cylinder, and then the driver side wheel.
N e v e r r e u s e a n y
e x c e s s f l u i d o r
return to the original
container. Dispose of brake fluid properly.
An assistant will be necessary to perform this
procedure.
Use a clean cloth to wipe off the master cylinder reservoir
and wheel cylinder bleeder valves (Ref Fig. 7 on page D-
!
!
!
!
Summary of Contents for WorkHorse ST 480
Page 2: ......
Page 3: ......
Page 4: ......
Page 5: ......
Page 6: ......
Page 7: ......
Page 8: ......
Page 9: ......
Page 10: ......
Page 11: ......
Page 12: ......
Page 13: ......
Page 14: ......
Page 15: ......
Page 16: ......
Page 17: ......
Page 18: ......
Page 19: ......
Page 20: ......
Page 21: ......
Page 22: ......
Page 23: ......
Page 24: ......
Page 25: ......
Page 26: ......
Page 27: ......
Page 28: ......
Page 29: ......
Page 30: ......
Page 31: ......
Page 32: ......
Page 33: ......
Page 34: ......
Page 35: ......
Page 36: ......
Page 37: ......
Page 38: ......
Page 39: ......
Page 40: ......
Page 41: ......
Page 42: ......
Page 43: ......
Page 44: ......
Page 57: ......
Page 58: ......
Page 59: ......
Page 60: ......
Page 61: ......
Page 62: ......
Page 63: ......
Page 64: ......
Page 65: ......
Page 66: ......
Page 67: ......
Page 68: ......
Page 69: ......
Page 70: ......
Page 71: ......
Page 72: ......
Page 73: ......
Page 74: ......
Page 75: ......
Page 76: ......
Page 77: ......
Page 78: ......
Page 79: ......
Page 80: ......
Page 81: ......
Page 82: ......
Page 83: ......
Page 84: ......
Page 85: ......
Page 86: ......
Page 87: ......
Page 88: ......
Page 89: ......
Page 90: ......
Page 91: ......
Page 92: ......
Page 93: ......
Page 94: ......
Page 95: ......
Page 96: ......
Page 97: ......
Page 98: ......
Page 99: ......
Page 100: ......
Page 101: ......
Page 102: ......
Page 103: ......
Page 104: ......
Page 105: ......
Page 106: ......
Page 107: ......
Page 108: ......
Page 109: ......
Page 110: ......
Page 111: ......
Page 112: ......
Page 113: ......
Page 114: ......
Page 115: ......
Page 116: ......
Page 117: ......
Page 118: ......
Page 119: ......
Page 120: ......
Page 121: ......
Page 122: ......
Page 123: ......
Page 124: ......
Page 125: ......
Page 126: ......
Page 127: ......
Page 128: ......
Page 129: ......
Page 130: ......
Page 131: ......
Page 132: ......
Page 133: ......
Page 134: ......
Page 135: ......
Page 136: ......
Page 137: ......
Page 138: ......
Page 139: ......
Page 140: ......
Page 141: ......
Page 142: ......
Page 143: ......
Page 144: ......
Page 145: ......
Page 146: ......
Page 147: ......
Page 148: ......
Page 149: ......
Page 150: ......
Page 151: ......
Page 152: ......
Page 153: ......
Page 154: ......
Page 155: ......
Page 156: ......
Page 157: ......
Page 158: ......
Page 159: ......
Page 160: ......
Page 161: ......
Page 162: ......
Page 163: ......
Page 164: ......
