Hydraulic Line Replacement; Front Brake Line Removal; Front Brake Line Installation - Club Car Carryall 1500 Maintenance And Service Manual

HYDRAULIC AND PARK BRAKE SYSTEMS

HYDRAULIC LINE REPLACEMENT

See General Warnings, Section 1, Page 1-2.
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 6-15.
• 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.
NOTE: The brake lines are provided as assemblies without separating unions other than those at the wheels and
master cylinder.

FRONT BRAKE LINE REMOVAL

1. Chock the rear wheels and set the park brake.
2. Raise hood.
3. Use a flare-nut wrench to remove the front brake line at the master cylinder. See following NOTE.
NOTE: Place a plastic bag around the master cylinder to catch brake fluid before the brake line is removed. Wrap the
bag around the master cylinder to prevent debris from entering the brake line port.
4. Remove the front brake lines, banjo bolts and copper washers at each front wheel caliper assembly.
NOTE: Place a pan under each caliper assembly to collect brake fluid.
Place a plastic bag around each caliper to prevent debris from entering the brake line ports. Do not allow
brake fluid to contact the brake pads and disc.
5. Remove the two brake line support brackets, T-bracket and P-clamp from the frame.
6. Slide the front brake lines toward the front of the vehicle, away from the master cylinder.

FRONT BRAKE LINE INSTALLATION

1. Feed the new front brake line under the front of the vehicle and up to the master cylinder.
2. Carefully insert the flared end of the brake line end into the master cylinder and tighten the hardware to 132
in-lb (15 N·m).
3. Install the T-bracket on the frame and tighten the hardware to 50 in-lb (5.6 N·m) (Figure 6-7, Page 6-12). Install
the P-clamp on the frame and tighten the hardware to 85 in-lb (9.6 N·m).
4. Install the two support brackets and tighten the hardware to 50 in-lb (5.6 N·m) (Figure 6-8, Page 6-12).
2015 Carryall 1500/1700 and XRT 1550 Maintenance and Service Manual
Hydraulic Line Replacement
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Page 6-11