Rear Brake Shoe Adjuster Installation; Hydraulic Line And Hose Replacement; Front Brake Line Removal - Club Car TURF 272 Maintenance Manual

MC010C-BS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS

REAR BRAKE SHOE ADJUSTER INSTALLATION

NOTE: The adjusters must be replaced as pairs using new hardware.
1. Install bolt (4) through flat washer (2) and through the brake cluster back plate (1) (Figure 6b-21,
Page 6b-25).
2. Apply a light coat of grease to the Bellville washer (5) and install the washer onto the bolt (4) and against
the inside surface of the back plate (1) (Figure 6b-21, Page 6b-25).
3. Carefully apply Loctite 222 to the threaded portion of bolt (4) and attach the adjuster arm (3). Position
adjuster so that the brake mounting post is to the top of the back plate (Figure 6b-21, Page 6b-25).
4. Grip the adjuster arm (3) with a pair of locking pliers. Use a Torx #T-27 driver or 7/16-inch socket to tighten
the bolt (4) to 115 in-lb (13 N·m) (Figure 6b-21, Page 6b-25).
5. Repeat steps 1 through 4 for the remaining adjuster.
6. Install rear brake cluster assembly. See Rear Brake Cluster Assembly Installation on page 6b-22.
7. Install rear brake shoes. See Rear Brake Shoe Installation on page 6b-16.
8. Install rear brake drum. See Rear Wheel Brake Drum Installation on page 6b-19.
9. Repeat steps 1 through 8 for the opposite rear wheel if necessary.
10. Bleed the rear brakes. See Bleeding the Hydraulic Brake System on page 6b-33.
11. Perform all of the brake system inspections to ensure that both the hydraulic brake system and the park
brake system are adjusted and operating correctly before placing the vehicle into service. See Brake
System Inspection on page 6b-3.

HYDRAULIC LINE AND HOSE REPLACEMENT

Read DANGER and WARNING on page 6b-1.
∆
WARNING
• To perform any of the following procedures, the hydraulic system must be opened. As a
result, the brakes must be bled after the correct reinstallation of the brake components.
Failure to bleed the brakes could result in decreased braking performance due to air being
trapped in the hydraulic system. Use only DOT 5 brake fluid. See Bleeding the Hydraulic Brake
System on page 6b-33.
• Prior to servicing hydraulic brakes, thoroughly clean the vehicle, paying particular attention
to areas immediately surrounding hydraulic connections, to prevent dirt or debris from
entering system.

FRONT BRAKE LINE REMOVAL

1. Place chocks at the rear wheels, release the park brake and lift the front of the vehicle with a chain hoist
or floor jack. Place jack stands under the outer front frame I-beam of the vehicle, and lower the floor jack
or chain hoist so that the vehicle is resting on the jack stands. See Figure 5-2, Section 5, Page 5-4.
2. Drill the rivet (8) securing the brake line (4) to the vehicle frame (Figure 6b-22, Page 6b-28).
3. Place a pan below the vehicle to collect the brake fluid when the hydraulic system is opened in the fol-
lowing step.
4. Using a 7/16-inch flare nut wrench, remove the flare nut of the front brake line (4) from the master cylinder
(Figure 6b-22, Page 6b-28).
5. Using a 3/8-inch flare nut wrench, remove the opposite end of the brake line (4) from the T-manifold block
(1) (Figure 6b-22, Page 6b-28).
2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual
Hydraulic Line and Hose Replacement
Page 6b-27
6B