Club Car Carryall 1500 Maintenance And Service Manual page 66

6
Brake Pads and Caliper
WARNING
• To reduce the possibility of diminished brake performance or failure, never use petroleum-based
lubricants on brake system components, and ensure lubricant does not contact friction surfaces of
brake pads or rotors.
Rear Brake Pads Only: If new pads will not easily slide into place over the brake disc once the piston is fully
retracted, perform the following steps.
1.1. Loosen the park brake lever adjustment bolt jam nut (1) (Figure 6-6, Page 6-9).
1.2. Carefully back out the adjustment bolt (2) one turn at a time to gain additional clearance. See following
CAUTION.
CAUTION
• Do NOT exceed the 1.7 in. (43.2 mm) dimension (A) (Figure 6-6, Page 6-9) when backing out the
adjustment bolt (2). If dimension is exceeded, the bolt will lose contact with the internal o-ring (3), and
brake fluid will leak out of caliper bore.
1.3. After each turn, retract caliper piston and attempt to install caliper and new pads onto brake disc.
NOTE: If the caliper appears to have a leak shortly after servicing the brakes (pads or park brake adjustment) or the
car has a spongy brake pedal, it is possible that the service caused the leak as described above.
There are three likely scenarios for this condition:
– 1) The bolt was backed out too far, and was not re-adjusted properly.
Symptoms: The brake pedal could be really soft and a significant amount of brake fluid could be leaking.
What to do: Re-adjust the bolt properly. The bolt will contact the o-ring again and should prevent further
leaks. Clean leaking brake fluid from caliper and check for continued leakage.
– 2) The bolt was backed out too far, but was re-adjusted properly.
Symptoms: Some brake fluid will leak initially.
What to do: Because the bolt was re-adjusted correctly, the bolt contacted the o-ring and should prevent
further leaks. Clean leaking brake fluid from caliper and check for continued leakage.
– 3) The caliper is defective and will need to be replaced. See Brake Pad and Caliper Removal on
page 6-6.
In any of these three cases, the brake caliper must be purged of air. See Bleeding the Hydraulic Brake
System on page 6-15. Once purged, the spongy brake pedal should disappear. The residual fluid
that seeped past the seal will still appear as a leak, however if the brakes are working correctly, further
service/replacement is not necessary.
Page 6-8 2015 Carryall 1500/1700 and XRT 1550 Maintenance and Service Manual
HYDRAULIC AND PARK BRAKE SYSTEMS