HYDRAULIC AND PARK BRAKE SYSTEMS
Brake Shoe Adjuster Replacement
Page 6-22 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual
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3. Remove brake shoes. See Brake Shoe Removal on page 6-9.
4. Remove brake cluster assembly. See Front Brake Cluster Removal on page 6-17.
5. Grip adjuster arm (3) with a pair of locking pliers and remove the bolt (4) on the back side of the backing
plate with a wrench or socket (Figure 6-1, Page 6-2 or Figure 6-18, Page 6-20).
6. Remove and discard all adjuster components (3, 4, and 5) (Figure 6-1, Page 6-2 or Figure 6-18, Page
7. Clean the backing plate surfaces that contact the adjuster.
8. Repeat steps 1 through 7 for the remaining adjuster. The adjusters must be replaced as pairs.
BRAKE SHOE ADJUSTER INSTALLATION
1. Apply a light coat of grease to the belleville washer (5) and install the washer onto the adjuster arm (3)
as shown (Figure 6-1, Page 6-2 or Figure 6-18, Page 6-20).
2. Carefully apply Loctite
®
222 to the bolt (4) (Figure 6-1, Page 6-2 or Figure 6-18, Page 6-20).
3. Insert the nose of the tube nut (2) into the backing plate (1). Tighten the bolt to 115 in-lb (13 N·m) (Fig-
ure 6-1, Page 6-2 or Figure 6-18, Page 6-20).
4. Install brake cluster assembly. See Brake Cluster Replacement on page 6-17.
5. Install brake shoes. See Brake Shoe Installation on page 6-12.
6. Install rear axle if required.
NOTE: Clean any residual oil from the exposed end of the axle shaft and from the oil seal area prior to
installing the axle shaft.
6.1. Clean the axle shaft and splines and then insert the shaft, splined end first, through the seal and
into the axle tube. Be careful not to damage the seal. Advance the shaft through the inner bearing
and rotate it to align the shaft splines with the splined bore of the differential side gear. Continue
advancing the shaft until the bearing seats against the axle tube shoulder.
6.2. Install retaining ring in the axle tube (Figure 6-4, Page 6-9).
6.3. Place a 1/4 to 3/8 inch (6-10 mm) diameter rod against the retaining ring and tap lightly at four to
five locations to ensure it is properly seated. See following WARNING.
∆ WARNING
• Be sure retaining ring is properly seated in its 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 vehicle control could result in severe personal injury or death.
7. Perform all of the brake system inspections to ensure that both the hydraulic brake system and the park
brake system are adjusted and operating correctly before placing the vehicle into service. See Brake
