WHEEL BRAKE ASSEMBLIES
Brake Cluster Removal and Installation
2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual
Page 6-9
6
5.1. Using 90° snap ring pliers (CCI P/N 1012560), remove the axle retaining ring (1)
(Figure 6-2,
Page 6-2)
.
5.2. Pull the axle shaft (2) from the axle tube
(Figure 6-2, Page 6-2)
.
6. Remove bow-tie pin (13) and clevis pin (12) from brake cable
(Figure 6-4, Page 6-3)
.
7. Remove four bolts (11) and lock nuts (10) that mount the brake assembly to the transaxle
(Figure 6-4,
Page 6-3)
.
8. Remove brake assembly from transaxle.
BRAKE CLUSTER INSTALLATION
1. Install in reverse order of disassembly. Use new bow-tie pins when installing brake cables.
See follow-
ing CAUTION.
ý
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.
4.1. Insert the splined end of the axle shaft into the axle tube. Be careful not to damage the seal on the
inside of the axle tube hub. Advance the shaft through to the bearing on the shaft, and rotate it to
align the shaft splines with the splined bore of the differential gear. Continue advancing the shaft
until the bearing on the axle is firmly seated within the axle tube hub seal.
4.2. Use a 90° internal snap ring pliers (.090 tip) to attach the internal retaining ring into the axle tube
hub so that it seats against the axle bearing assembly and into the machined slot in the inside wall
of the axle tube hub.
4.3. Place a 1/4 to 3/8 - inch (6 - 10 mm) diameter rod against the retaining ring and tap lightly at four
or five locations to ensure it is properly seated.
See following WARNING.
ý
WARNING
• Be sure retaining ring is properly seated in groove. If ring is not properly installed, the axle
assembly will separate from the transaxle and damage the axle assembly and other
components. Loss of control of the vehicle could result in severe personal injury or death.
5. Tighten lug nuts on rear wheels, using crisscross pattern, to 55 ft-lb (74.6 N·m).
See Wheel Installation,
Section 8, Page 8-1.
6. Adjust the brakes.
See Brake Adjustment on page 6-8.
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