Replacement Of Wear Items; Brake Pad Replacement; Spindle Replacement; Actuator Linkage Bushings - Cushman 632904 Service Manual

BRAKES
Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
ROUTINE MAINTENANCE (Con-
B
tinued)
The brake fluid should be checked at regular intervals
(as specified in the Periodic Service Schedule) or imme-
diately if fluid leaks are found. The easiest way to check
fluid level is to clean the cap with a shop rag and remove
the cap. Check fluid level using a mechanics mirror and
a flashlight. Add fluid if the level has fallen below 1/4"
from the top of the reservoir and inspect for visible fluid
leaks.
Never work on a vehicle supported by a jack
alone. To prevent possible personal injury, the
vehicle must be supported on jack stands dur-
ing this procedure.

REPLACEMENT OF WEAR ITEMS

Brake Pad Replacement

Brake pads should always be replaced as a full set of
four pads. To remove the brake pads, raise the vehicle
per 'Lifting the Vehicle' in the SAFETY section. Loosen
both of the bolts securing the caliper to the spindle but
only remove one. Swing the caliper free from the rotor.
Push out the two guide/retainer pins from the caliper and
remove the pads, being careful to note the orientation of
the brake pads. Install a new set of pads. If the pads
have been correctly oriented, the guide pins will easily
engage. Re-insert the guide/retainer pins, being sure
that they are correctly seated in the grooves machined
in the caliper casting. Gently push the pads away from
each other to provide adequate clearance with the rotor
and then swing the entire caliper and pad assembly
back over the rotor. Secure the caliper to the spindle and
tighten both bolts to 25 - 30 ft. lbs. (33.8 - 40.6 Nm)
torque. NOTE: Unless fluid is lost or a brake line is dis-
connected, there is no need to bleed the system.
For Hub Replacement, Wheel Bearing and Race
Replacement, Wheel Bearing Packing and Wheel Bear-
ing Adjustment procedures, see FRONT SUSPENSION
AND STEERING.

Spindle Replacement

See FRONT SUSPENSION AND STEERING.
Page E-8

Actuator Linkage Bushings

Removing the front shield may improve access (See
BODY)
The actuator linkage is connected to the lower actuator
pivot with a flat washer and cotter pin. Remove and dis-
card the cotter pin and remove the washer. A new nylon
bushing may be installed (flange down) to the lower
actuator pivot and the actuator linkage reinstalled using
a new cotter pin. The actuator linkage is connected to
the brake pedal arm with a flat washer and cotter pin.
Remove and discard the cotter pin and remove the
washer. A new nylon bushing may be installed (with the
flange between the actuator linkage and the brake pedal
arm) to the lower actuator pivot and the actuator linkage
reinstalled using a new cotter pin.

BLEEDING BRAKES

Tool List
Hose ........................................................................A/R
Clean Container ...........................................................1
Brake Fluid, DOT 3 ..................................................A/R
Wrench, 1/4" box end ..................................................1
The hydraulic brake system must be free of air to oper-
ate properly. Air can enter the system when hydraulic
parts are disconnected for servicing or replacement, or
when the fluid level in the master cylinder reservoir is
very low. Air in the system will give the brake pedal a
spongy feeling upon application.
An assistant will be necessary to perform this procedure.
Use a clean cloth to wipe off the master cylinder reser-
voir and wheel cylinder bleeder valves (Ref. Fig. 1).
Clean each fitting before opening to prevent contaminat-
ing the system. Open the master cylinder reservoir and
top off with standard automotive DOT 3 brake fluid.
Never reuse any excess fluid or return to the
original container. Dispose of brake fluid prop-
erly.
Brake fluid should never be returned to the original con-
tainer and reused due to the possibility of contamination
by dirt, grease, moisture or used brake fluid which could
Repair and Service Manual
NOTICE
Qty.