Seat Support Removal ............................................................................................................................. 4-10

Seat Support Installation .......................................................................................................................... 4-10

Seat Belts ................................................................................................................................................... 4-10

Bench Seat Belt Removal......................................................................................................................... 4-10

Bench Seat Belt Installation.......................................................................................................................4-11

Cargo Bed - Electric Lift................................................................................................................................4-11

Testing the Bed Lift Motor..........................................................................................................................4-11

Bed Lift Motor Removal.............................................................................................................................4-11

Bed Lift Motor Installation ......................................................................................................................... 4-12

Cargo Bed Removal ................................................................................................................................ 4-12

Cargo Bed Installation.............................................................................................................................. 4-12

Cargo Bed - Manual Lift............................................................................................................................... 4-13

Cargo Bed Removal ................................................................................................................................ 4-13

Cargo Bed Installation.............................................................................................................................. 4-13

Rear Fender................................................................................................................................................ 4-14

Rear Fender Removal.............................................................................................................................. 4-14

Rear Fender Installation ........................................................................................................................... 4-14

SECTION 5 - ACCELERATOR AND BRAKE PEDAL ASSEMBLIES................................................................... 5-1

Accelerator Pedal .......................................................................................................................................... 5-1

Accelerator Pedal Removal ........................................................................................................................ 5-1

Accelerator Pedal Installation ..................................................................................................................... 5-2

Brake Pedal .................................................................................................................................................. 5-3

Brake Pedal Removal ................................................................................................................................ 5-3

Brake Pedal Installation ............................................................................................................................. 5-3

Brake Pedal Adjustment............................................................................................................................. 5-3

Park Brake Pedal........................................................................................................................................... 5-4

Park Brake Pedal Assembly Removal ......................................................................................................... 5-4

Park Brake Pedal Assembly Installation ...................................................................................................... 5-4

SECTION 6 - HYDRAULIC AND PARK BRAKE SYSTEMS ................................................................................ 6-1

Brake System Inspection................................................................................................................................ 6-1

Brake Pedal Inspection .............................................................................................................................. 6-1

Master Cylinder Inspection ......................................................................................................................... 6-2

Brake Line Inspection ................................................................................................................................ 6-3

Park Brake Inspection ................................................................................................................................ 6-3

Brake Disc and Pad Inspection ................................................................................................................... 6-3

Brake System Troubleshooting ....................................................................................................................... 6-4

Brake Pads and Caliper ................................................................................................................................. 6-6

Brake Pad and Caliper Removal ................................................................................................................. 6-6

Brake Pad and Caliper Installation .............................................................................................................. 6-7

Brake Discs................................................................................................................................................. 6-10

Disc Removal .......................................................................................................................................... 6-10

Disc Installation ....................................................................................................................................... 6-10

Hydraulic Line Replacement..........................................................................................................................6-11

Front Brake Line Removal.........................................................................................................................6-11

Front Brake Line Installation ......................................................................................................................6-11

Rear Brake Line Removal ........................................................................................................................ 6-12

Rear Brake Line Installation...................................................................................................................... 6-13

Master Cylinder and Reservoir ..................................................................................................................... 6-14

Filling the Hydraulic System ..................................................................................................................... 6-14

Master Cylinder Removal ......................................................................................................................... 6-14

Master Cylinder Installation ...................................................................................................................... 6-14

Bleeding the Hydraulic Brake System ........................................................................................................... 6-15

Bleeding Brakes on a DOT 5 Fluid Filled System ....................................................................................... 6-15

Purging the Hydraulic System................................................................................................................... 6-17

Park Brake System ...................................................................................................................................... 6-18

Park Brake Adjustment - At Rear Calipers ................................................................................................ 6-18

Front Park Brake Cable Adjustment - Cable Only System .......................................................................... 6-18

Park Brake Wheel Cables ........................................................................................................................ 6-19

Front Park Brake Cable Removal - Cable Only System ............................................................................. 6-20

Front Park Brake Cable Installation - Cable Only System........................................................................... 6-21

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2015 Carryall 1500/1700 and XRT 1550 Maintenance and Service Manual

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