BRAKES
4 - 5
November 2007
GEM Service Manual
OPERATION
FRONT BRAKE ASSEMBLY
When applying the brake pedal, pedal pressure
forces the brake fluid through the brake line, from
the master cylinder to each caliper. This pressure
pushes the caliper piston out, causing the brake
pads to press against the brake rotor, which stops
the rotation of the rotor and wheel.
DESCRIPTION
The front brake assembly consists of a caliper,
rotor and brake pads. The rotor and caliper are
mounted to the steering knuckle. A half shaft (drive
shaft) engages splines on the spindle, and is
attached by a nut and washer.
REMOVAL
1. Raise and support the vehicle on a suitable
hoist.
2. Remove the hubcap.
3. Remove the tire and wheel assembly.
4. Disconnect the brake hose from the caliper.
Allow fluid to drain into suitable container for
disposal.
5. Remove the bolts and the brake caliper.
6. Remove the hub spacer plate.
7. Remove 15/16" drive shaft cotter pin and
retaining nut.
8. Remove the hub and rotor assembly.
9. Remove the four screws and the rotor
assembly.
INSTALLATION
1. Install the rotor on the hub and install the four
screws. Apply Loctite
®
242 to the threads and
tighten the screws to 15 ft-lb.
2. Install the rotor and hub assembly onto the
vehicle.
3. Install and tighten snugly the 15/16" drive shaft
retaining nut and washer.
4. Install the hub spacer plate.
5. Install the brake caliper and tighten the bolts to
20 ft-lb.
6. Connect the brake hose to the caliper using
new washers. Tighten the bolt to 20 ft-lb.
Fig 4 Front Brake Breakdown
(* indicates serviceable part)
7. Install the tire and wheel assembly. Tighten the
lug nuts to 65 ft-lb.
1 - Hub*
6 - Brake Line*
2 - Rotor*
7 - Brake Line Washer*
3 - Rotor Mounting Bolts*
8 - Front Brake Caliper
4 - Caliper Mounting Bolts*
9 - Spacer Plate*
5 - Brake Line Mounting Bolt*
8. Back off drive shaft retaining nut, apply Loctite®
242 and tighten to 65 ft-lb. Install the cotter pin.
9. Install the hubcap.
10.
Bleed the brakes. See Brake Bleeding
instructions in this section.
Summary of Contents for GEM E Series
Page 2: ......
Page 87: ...ELECTRICAL 5 40 November 2007 GEM Service Manual ...
Page 95: ...ELECTRICAL 5 48 November 2007 GEM Service Manual ELECTRICAL OVERVIEW ...
Page 97: ...ELECTRICAL 5 50 November 2007 GEM Service Manual POWER DISTRIBUTION ...
Page 98: ...5 51 ELECTRICAL GEM Service Manual November 2007 CHARGING SYSTEM ...
Page 99: ...ELECTRICAL 5 52 November 2007 GEM Service Manual CHARGING SYSTEM CONTINUED e6S eLXD OPTION ...
Page 100: ...5 53 ELECTRICAL GEM Service Manual November 2007 PARK BRAKE CIRCUIT ...
Page 101: ...ELECTRICAL 5 54 November 2007 GEM Service Manual DC DC CONVERTER ...
Page 102: ...5 55 ELECTRICAL GEM Service Manual November 2007 MAIN CONTACTOR ...
Page 103: ...ELECTRICAL 5 56 November 2007 GEM Service Manual MAIN CONTACTOR CONTINUED e6S eLXD OPTION ...
Page 104: ...5 57 ELECTRICAL GEM Service Manual November 2007 MOTOR CONTROLLER SYSTEM ...
Page 105: ...ELECTRICAL 5 58 November 2007 GEM Service Manual MOTOR CONTROLLER SYSTEM CONTINUED ...
Page 106: ...5 59 ELECTRICAL GEM Service Manual November 2007 DISPLAY RD ...
Page 107: ...ELECTRICAL 5 60 November 2007 GEM Service Manual DISPLAY CONTINUED ...
Page 108: ...5 61 ELECTRICAL GEM Service Manual November 2007 DISPLAY CONTINUED ...
Page 109: ...ELECTRICAL 5 62 November 2007 GEM Service Manual HORN POWER OUTLET ...
Page 110: ...5 63 ELECTRICAL GEM Service Manual November 2007 HEATER ...
Page 111: ...ELECTRICAL 5 64 November 2007 GEM Service Manual DASH FAN ...
Page 112: ...5 65 ELECTRICAL GEM Service Manual November 2007 SECURITY LIGHT BAR ...
Page 113: ...ELECTRICAL 5 66 November 2007 GEM Service Manual AUDIO SYSTEM ...
Page 115: ...ELECTRICAL 5 68 November 2007 GEM Service Manual FRONT LIGHTING EXCEPT NEW YORK ...
Page 116: ...5 69 ELECTRICAL GEM Service Manual November 2007 FRONT LIGHTING NEW YORK ...
Page 117: ...ELECTRICAL 5 70 November 2007 GEM Service Manual REAR LIGHTING EXCEPT NEW YORK ...
Page 118: ...5 71 ELECTRICAL GEM Service Manual November 2007 REAR LIGHTING NEW YORK ...
Page 119: ...ELECTRICAL 5 72 November 2007 GEM Service Manual REAR LIGHTING ...
Page 120: ...5 73 ELECTRICAL GEM Service Manual November 2007 REAR LIGHTING CONTINUED ...
Page 121: ...ELECTRICAL 5 74 November 2007 GEM Service Manual TURN SIGNAL REMINDER CIRCUIT ...
Page 122: ...5 75 ELECTRICAL GEM Service Manual November 2007 WIPER WASHER ...
Page 156: ...7 9 BODY INSTALLATION OF SCUFF GUARDS CONTINUED 10 Finish e4 GEM Service Manual November 2007 ...