Pioneer 1200, Maintenance Service Manual

Page: 63 / 300

MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake Cluster Assembly Replacement
2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 6-17
6
5. Install the wheel and finger-tighten the lug nuts (21) (Figure 6-19, Page 6-21).
6. Repeat steps 1 through 5 for the opposite rear wheel as required.
7. Lower the vehicle and finish tightening the lug nuts, using a crisscross pattern, to 55 ft-lb (74.6 N·m).
8. Perform all of the brake system inspections. See Brake System Inspection on page 6-1.
BRAKE CLUSTER ASSEMBLY REPLACEMENT
See General Warning, Section 1, Page 1-1.
∆
WARNING
• To perform this procedure, 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 6-31.
• Worn or damaged brake drums must not be machined. Replace as necessary.
• Use only approved replacement brake drums designed for your vehicle. For MC012C-AS00
transaxles, use CCI P/N 102264701.
FRONT BRAKE CLUSTER ASSEMBLY REMOVAL
1. Remove front wheel brake drum. See Front Wheel Brake Drum Removal on page 6-6.
2. Remove the banjo bolt (16) and copper washers (17) (Figure 6-1, Page 6-2).
3. Lift the hose above the brake cluster assembly and place a plastic bag over the hose fitting to keep dirt
and debris from entering the hydraulic brake system (Figure 6-15, Page 6-17).
4. Use a Torx #T-40 driver and remove the four Torx-head bolts (18), washers (19) and lock nuts (20) that
secure the brake cluster and back plate assembly to the front spindle plate (Figure 6-1, Page 6-2).
FRONT BRAKE CLUSTER ASSEMBLY INSTALLATION
1. Install the back plate to the front spindle flange with four new Torx-head bolts (18), washers (19) and lock
nuts (20). Tighten all four bolts to 76 in-lb (8.6 N·m) (Figure 6-1, Page 6-2). See following CAUTION.
Figure 6-15 Front Brake Hose With Plastic Bag
WIRE TIE
PLASTIC
BAG
FLEX BRAKE
HOSE