Replacing An Adjuster; Belleville Washer Installation - Ezgo WorkHorse ST 480 Technician's Repair And Service Manual

BRAKES
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings
ing edges. If the brake shoe thickness is approaching
.06" (1.5 mm), it is recommended that the shoes be
replaced. It is recommended that the brake shoe springs
and brake adjusters be replaced when installing new
brake shoes
Check springs for loss of tension and damage. Replace
weak springs and any damaged or badly worn parts.
Check adjuster operation. Insure that each adjuster will
move with approximately 30 - 50 in. lbs. (3.4 - 5.6 Nm) of
torque. If adjusters are frozen, badly worn or loose,
replace the adjuster assembly. See 'Replacing an
Adjuster' on page D-8.
Replace the wheel cylinder if there is any sign of leak-
age.
Insure that the parking lever and strut assembly can be
easily moved by hand. If necessary, this assembly can
be serviced as follows:
Disassemble by removing the C-clip. Wire brush contact
surfaces to remove any corrosion and contaminants.
Lightly grease the pin and contact surfaces before re-
assembly.
!
when finished. Failure to do so could result
in a non-functioning parking brake if the clip
comes off.
Reassembly
Apply a light coat of high temperature lubricant to shoe
support points on the backing plate, to adjuster pin, and
to anchor.
Position the adjusters so that the pins are at the 12
o'clock position.
If the wheel cylinder was removed, install it now into the
backing plate. Insert and tighten the wheel cylinder
mounting bolts to 120 in. lbs. (14 Nm) torque. Reconnect
and tighten the brake fluid line to 124 - 177 in. lbs. (14 -
20 Nm) torque.
Position shoes on backing plate and install hold-down
springs.
Install parking brake strut with tab on strut engaged in
brake shoe web.
Place upper end of shoe webs against wheel cylinder,
and install upper shoe-to-shoe spring. Remove wheel
cylinder clamp.
Install lower shoe-to-shoe spring.
Page D-8
Insure that the C-
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clip is completely
seated in its' groove
Repair and Service Manual
Install wheel and drum. See 'BRAKE DRUM REMOVAL
AND INSTALLATION' on page D-5.
Pre-adjust shoes by rotating adjuster nut away from the
axle until shoes contact drum and then back off just
enough to eliminate drag.

Replacing an Adjuster

Replace the adjuster assembly if the adjuster requires
more than 50 in. lbs. (5.6 Nm) torque to rotate.
Secure the adjuster arm with locking pliers and remove
the bolt on the back side of the backing plate with a
wrench or socket. The bolt may shear off which is
acceptable. Remove and discard all adjuster compo-
nents. Clean the backing plate surfaces that contact with
the adjuster.
Prepare to install the new adjuster by applying a light
coat of grease to the belleville washer. Install the washer
onto the adjuster arm with arch up as shown in the illus-
tration (Ref Fig. 6 on page D-8).
Bolt
Backing
Plate
Fig. 6 Belleville Washer Installation
Apply thread locking compound to the bolt.
Insert the nose of the tube nut into the backing plate.
Install the bolt into the tube nut and tighten to 110 - 120
in. lbs. (12 - 14 Nm) torque.
Although not strictly necessary, it is recommended to
replace both adjusters if one is found to require replace-
ment.
Adjustment
After the brake system has been bled, make 3 to 10 for-
ward and reverse stops by applying firm pressure to the
brake pedal on each stop to bring shoes to proper adjust-
ment.
Washer
Install Belleville
Washer With
Arch Up As
Shown
Adjuster
Tube
Nut