Front Wheel Cylinder Installation; Rear Wheel Cylinder Removal; Rear Wheel Cylinder Installation - Pioneer 1200 Maintenance Service Manual

6
MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS
Front Wheel Cylinder Removal, Continued:
3. Remove the banjo bolt (16) and two copper washers (17) (Figure 6-1, Page 6-2).
4. 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).
5. Remove two bolts (9) and lock washers that secure the wheel cylinder (7) to the brake cluster back plate
(1) (Figure 6-1, Page 6-2).
6. Repeat steps 1 through 5 for the remaining front wheel if necessary.

FRONT WHEEL CYLINDER INSTALLATION

1. Install wheel cylinder (7) with two new bolts (9) and lock washers (Figure 6-1, Page 6-2). Tighten bolts
to 120 in-lb (13 N·m).
2. Install a new banjo bolt (16) and new copper washers (17) to the wheel cylinder (7). Position the elbow
of the brake hose toward the rear of the vehicle. Tighten bolt to 13 ft-lb (17.6 N·m).
3. Install front brake shoes. See Front Brake Shoe Installation on page 6-12.
4. Install front wheel brake drum. See Front Wheel Brake Drum Installation on page 6-14.
5. Repeat steps 1 through 4 for the remaining front wheel if necessary.
6. Bleed the front wheel brakes. See Bleeding the Hydraulic Brake System on page 6-31.
7. Perform all of the brake system inspections. See Brake System Inspection on page 6-1.

REAR WHEEL CYLINDER REMOVAL

1. Remove rear wheel brake drum. See Rear Wheel Brake Drum Removal on page 6-8.
2. Remove rear brake shoes. See Rear Brake Shoe Removal on page 6-9.
3. Use a 3/8-inch flare nut wrench and remove the brake hose fitting from the rear wheel cylinder
(Figure 6-17, Page 6-18).
4. 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 6-18, Page 6-19).
5. Remove two bolts (9) and lock washers that secure the wheel cylinder to the mounting plate (1), and
remove the wheel cylinder (7) (Figure 6-19, Page 6-21).
6. Repeat steps 1 through 5 for the remaining rear wheel if necessary.

REAR WHEEL CYLINDER INSTALLATION

1. Install wheel cylinder (7) with two new bolts (9) and lock washers and tighten the two bolts to 120 in-lb
(13 N·m) (Figure 6-19, Page 6-21).
2. Connect the brake hose fitting to the wheel cylinder and tighten the flare nut fitting to 11 ft-lb (14.9 N·m).
3. Install rear brake shoes. See Rear Brake Shoe Installation on page 6-12.
4. Install rear wheel brake drum. See Rear Wheel Brake Drum Installation on page 6-16.
5. Repeat steps 1 through 4 for the remaining rear wheel if necessary.
6. Bleed the rear wheel brakes. See Bleeding the Hydraulic Brake System on page 6-31.
7. Perform all of the brake system inspections. See Brake System Inspection on page 6-1.
Page 6-20 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual
Wheel Cylinder Replacement