Front Caliper Removal; Front Caliper Installation - Club Car Carryall 1500 2016 Maintenance And Service Manual

HYDRAULIC BRAKE AND PARK BRAKE
SYSTEMS

FRONT CALIPER REMOVAL

WARNING
• If at any point in this procedure the hydraulic system is opened, 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 6-18.
• 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 the system.
CAUTION
• Do not pump the brake pedal without brake fluid in the master cylinder and reservoir.
• Worn or damaged brake discs cannot be machined to refinish them. Replace as necessary.
1. Lift and support the front or entire vehicle and remove the wheel(s). See Lifting The Vehicle, Section 3,
Page 3-7.
2. Remove the banjo bolt (3) and copper washers (4) holding brake hose to caliper (Figure 6-2). Discard the
copper washers. See following NOTE.
NOTE: Place a clean, tray-type container below the caliper and brake hose assembly to catch brake fluid when the
brake hose and caliper body are separated.
3. If the caliper will be used again, plug the banjo bolt hole to prevent dirt and debris entering the caliper.
4. Place a plastic bag over the hose fitting to prevent dirt and debris entering the hose.
5. Remove the two socket-head bolts (5) securing the caliper assembly to the steering upright.
6. Lift the caliper assembly (1) off the steering upright and brake disc.

FRONT CALIPER INSTALLATION

WARNING
• If at any point in this procedure the hydraulic system is opened, 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 6-18.
1. Place the caliper assembly (1) onto the steering upright making sure the brake disc slides between the inner
and outer brake pads.
NOTE: To help prevent noise, a silicone-based brake lubricant may be applied to the surfaces (on the back side of
the brake pads) that contact the caliper. A thin film may also be applied to the slide-pins. Always follow
lubricant manufacturer's directions.
2016 Carryall 1500/1700 and XRT 1550 Maintenance and Service Manual
Brake Pads and Caliper
Page 6-9
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