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MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS
MASTER CYLINDER INSTALLATION
1. Install master cylinder (1) into mounting bracket (19) and insert push rod (3), then seat boot (2)
(Figure 6a-23, Page 6a-34).
2. Install the two bolts (7) and nylon lock nuts (8) that secure the master cylinder (1) to the master cylinder
mounting bracket (19). Tighten to 14 ft-lb (19 N·m) (Figure 6a-23, Page 6a-34).
3. Using a 7/16-inch flare nut wrench, attach brake line (4) to master cylinder and tighten flare nut fitting to
11 ft-lb (14.9 N·m) (Figure 6a-22, Page 6a-29).
4. Using a 3/8-inch flare nut wrench, attach brake lines (10 and 11) to master cylinder and tighten flare nut
fittings to 11 ft-lb (14.9 N·m) (Figure 6a-23, Page 6a-34).
5. Attach the two wires to the master cylinder pressure switch (no particular orientation) (4) (Figure 6a-23,
Page 6a-34).
6. Adjust the brake pedal as instructed in Section 5. See Brake Pedal Adjustment, Section 5, Page 5-6.
7. Fill the reservoir of the master cylinder and bleed the entire hydraulic brake system. See Bleeding the
Hydraulic Brake System on page 6a-33.
8. Perform all of the brake system inspections to ensure that both the hydraulic brake system and the park
brake system are in correct adjustment and are operating correctly before placing the vehicle into ser-
vice. See Brake System Inspection on page 6a-3.
BLEEDING THE HYDRAULIC BRAKE SYSTEM
Read DANGER and WARNING on page 6a-1.
To properly function, the hydraulic system must be free of air. Air in the hydraulic system will result in a
"spongy" brake pedal. Air enters the hydraulic system whenever the system is opened as a result of service,
or when a leak occurs. Air may also enter the system if the brakes are applied when there is very little hydrau-
lic fluid in the brake fluid reservoir.
The master cylinder controls two separate hydraulic sub-systems. The front two wheels are connected to the
smaller, front portion of the brake fluid reservoir, and the rear wheels are connected to the rear, larger portion
of the brake fluid reservoir. Depending on where the hydraulic system was opened, bleeding of only the front
or rear hydraulic brake sub-system may be required. In some situations, bleeding of both the front and rear
brake sub-systems will be required. To bleed both the front and rear hydraulic brake sub-systems, use the fol-
lowing procedure to first bleed the two front brakes and repeat the procedure to bleed the two rear brakes.
1. Check the brake pedal and master cylinder push rod for proper adjustment before proceeding. See
Brake Pedal Adjustment, Section 5, Page 5-6.
2. Chock the front wheels, release the park brake and lift the vehicle with a chain hoist or floor jack. Place
jack stands under the outer front I-beam frame at the weldments of the front cross tube, or under the rear
axle tubes for the rear wheels, to support the vehicle. Lower the floor jack or chain hoist so that the vehicle
is resting on the jack stands.
3. Remove the cap from the master cylinder reservoir and fill the reservoir with DOT 5 brake fluid.
4. Remove each wheel and gently adjust the clearance between the brake shoes and brake drum by turning
each of the two adjusters on the brake cluster as shown (Figure 6a-16, Page 6a-19). Use a torque
wrench and a Torx #T-27 driver or hydraulic brake adjuster (CCI P/N 102169401). See following CAU-
TION.
2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual
Bleeding the Hydraulic Brake System
Page 6a-33
6A
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