Rear Brake Hose Removal; Rear Brake Hose Installation; Master Cylinder And Bell Crank Replacement; Bell Crank Removal - Club Car TURF 272 Maintenance Manual

MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS

REAR BRAKE HOSE REMOVAL

1. Place chocks at the rear wheels, release the park brake and lift the rear of the vehicle with a chain hoist
or floor jack. Place jack stands under the rear axle tubes to support the vehicle and lower the floor jack
or chain hoist so that the vehicle is resting on the jack stands.
2. Place a pan below the vehicle to collect the brake fluid when the hydraulic system is opened in the fol-
lowing steps.
3. Using a 3/8-inch flare nut wrench, remove the brake hose from the rear brake wheel cylinder assembly
(Figure 6a-19, Page 6a-22).
4. Using a 3/8-inch flare nut wrench, remove the rear brake line (10 or 11) from the rear brake hose at the
I-beam of the vehicle frame (Figure 6a-22, Page 6a-29).
5. Remove the horseshoe clip (12) that secures the rear brake hose (9) to the I-beam frame (Figure 6a-22,
Page 6a-29) and remove brake hose (9) through the D-shaped hole in the vehicle I-beam.
6. Repeat steps 3 through 5 for the opposite rear brake hose if necessary.

REAR BRAKE HOSE INSTALLATION

1. Install brake hose (9) through the D-shaped hole in I-beam, and install the horseshoe clip (12) that
secures the brake hose to the I-beam frame (Figure 6a-22, Page 6a-29).
2. Using a 3/8-inch flare nut wrench, attach the flare nut fitting the rear brake hose to the rear brake wheel
cylinder (Figure 6a-19, Page 6a-22). Tighten to 11 ft-lb (14.9 N·m).
3. Using a 3/8-inch flare nut wrench, install the rear brake line (10 or 11) to the rear brake hose (9) at the
I-beam of the vehicle frame (Figure 6a-22, Page 6a-29). Tighten to 11 ft-lb (14.9 N·m).
4. Repeat steps 1 through 3 for the opposite rear brake hose if necessary.
5. Fill the reservoir of the master cylinder and bleed the hydraulic system. See Bleeding the Hydraulic
Brake System on page 6a-33.
6. 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 6a-3.

MASTER CYLINDER AND BELL CRANK REPLACEMENT

Read DANGER and WARNING on page 6a-1.

BELL CRANK REMOVAL

1. Chock the wheels and release the park brake. Raise the passenger seat for access to the master cylinder
bell crank.
2. Remove the brake rod clevis bolt (6) and clevis (16) from the bell crank assembly (13) (Figure 6a-23,
Page 6a-34).
3. Remove the spring (18) from the bell crank (13) and master cylinder mounting bracket (19)
(Figure 6a-23, Page 6a-34).
4. Remove the push rod clevis bolt (20) and lock nut (21) from the bell crank (13) (Figure 6a-23,
Page 6a-34).
5. Remove the bell crank bolt (9) and nylon lock nut (11) from the master cylinder mounting bracket (19) and
remove bell crank (13) and two centering spacers (12) (Figure 6a-23, Page 6a-34).
2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual
Master Cylinder and Bell Crank Replacement
6A
Page 6a-31