Club Car Carryall 1500 2016, Maintenance And Service Manual

Page: 72 / 436

6
Brake Hose Replacement
HYDRAULIC BRAKE AND PARK BRAKE
SYSTEMS
BRAKE HOSE REPLACEMENT
See General Warnings, Section 1, Page 1-2.
WARNING
• To perform any of the following procedures, the hydraulic system must be opened. As a result, 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.
NOTE: The brake hoses are provided as assemblies without separating unions other than those at the wheels and
master cylinder.
FRONT BRAKE HOSE REMOVAL
1. Chock the rear wheels and set the park brake.
2. Raise hood.
3. Use a flare-nut wrench to remove the front brake hose at the master cylinder. See following NOTE.
NOTE: Place a plastic bag around the master cylinder to catch brake fluid before the brake hose is removed. Wrap
the bag around the master cylinder to prevent debris from entering the brake hose port.
4. Remove the banjo bolt and copper washers from each front caliper. (Figure 6-2, Page 6-8) .
NOTE: Place a pan under each caliper to collect brake fluid.
Place a plastic bag around each caliper to prevent debris from entering the brake hose ports. Do not allow
brake fluid to contact the brake pads and disc.
5. Unsnap the three brake hose clips.
6. Remove the screws that secure the T-bracket (1) to the frame (Figure 6-5) and P-clamps to the upper A-arms
(Figure 6-6, Page 6-15) .
7. Remove front brake hose from vehicle.
FRONT BRAKE HOSE INSTALLATION
1. Install new front brake hose following same routing as old brake hose.
2. Carefully insert the flared end of the brake hose end into the master cylinder and tighten the hardware to 132
in-lb (15 N·m).
3. Install the T-bracket (1) on the frame (Figure 6-5, Page 6-15) and P-clamps on the upper A-arms (Figure 6-6,
Page 6-15) . Tighten screws to 85 in-lb (9.6 N·m).
4. Secure the hoses in the three snap clips.
Page 6-14 2016 Carryall 1500/1700 and XRT 1550 Maintenance and Service Manual