Master Cylinder Replacement - Cushman 632904 Service Manual

Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
MASTER CYLINDER REPLACE-
MENT
During this process, it is likely that brake fluid will leak
from the master cylinder. Avoid allowing brake fluid to
contact the painted body components of the vehicle.
Wipe off immediately.
Removing the front shield may improve access (See
BODY Section).
To remove the master cylinder:
Turn vehicle key to 'OFF' and remove. Insure all optional
electrical accessories are turned OFF. At the battery,
remove the negative (-) cables. Cover top of battery with
a cloth or non-conductive material to prevent the possi-
bility of a dropped wrench or metal object from 'shorting
out' the battery.
Clean the area around the master cylinder to prevent dirt
and grease from contaminating the hydraulic system.
Disconnect wire terminal block from brake light switch
(Ref. Fig. 2).
Push Rod
Clevis Yoke
Linkage
Bell
Rod
Crank
Clevis
Yoke
Part of
Frame
Fig. 2 Replacing Master Cylinder
Disconnect primary brake line where it connects to flex-
ible brake hose. Provide a catch pan for the released
brake fluid. Remove clip anchoring flexible brake hose
to subframe.
Rubber
Boot
Washer
Brake
Light
Switch
Flexible
Brake
Hose
To
Primary Brake
Line
Repair and Service Manual
Disconnect clevis yoke from upper arm of bellcrank in
front of master cylinder. Disconnect linkage rod clevis
yoke from lower arm of bellcrank to allow bellcrank to
swing out of the way. Pull clevis yoke and push rod out
of master cylinder and remove boot.
Remove three lock nuts, lock washers and bolts and
remove master cylinder from vehicle.
Remove flexible brake hose from branch tee.
Remove brake light switch from branch tee.
Remove plug from branch tee.
Do not reuse existing branch tee on new master
cylinder.
Install new branch tee on new master cylinder using
teflon tape and tighten so that one of the three threaded
holes points straight down toward the ground at 70 - 80
in. lbs. (8 - 9 Nm) torque.
Install plug into branch tee using teflon tape and tighten
to 70 - 80 in. lbs. (8 - 9 Nm) torque.
Connect flexible brake hose to branch tee using teflon
tape and tighten to 190 - 200 in. lbs. (21.5 - 22.6 Nm)
torque. Anchor other end to subframe with clip. Con-
nect primary brake line to flexible brake hose and
tighten fitting to 70 - 80 in. lbs. (8 - 9 Nm) torque.
Install brake light switch into branch tee using teflon tape
and tighten to 70 - 80 in. lbs. (8 - 9 Nm) torque.
Mount master cylinder to frame bracket using new lock
nuts. Do not reuse original lock nuts. Tighten lock nuts to
28 - 32 in. lbs. (3 - 4 Nm) torque.
Insert push rod through rubber boot and washer into
master cylinder (make sure rod is through washer inside
boot). Snap rubber boot back onto master cylinder.
Install both clevis yokes back onto bellcrank using clevis
pins and new cotter pins.
Clip
To prevent brake failure resulting from con-
taminated brake fluid, never reuse any excess
fluid or return to the original container. Dis-
pose of brake fluid properly.
Fill reservoir with DOT 3 brake fluid and bleed brake
system. See "BLEEDING BRAKES" on page E- 8.
After bleeding brake system, check for leaks along all
lines and at master cylinder.
Connect the negative (-) battery cables.
B
BRAKES
B
Page E-3