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HYDRAULIC AND PARK BRAKE SYSTEMS
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.
6.
Remove each brake line from the grommet and clamp locations.
7.
Remove the T-bracket from the passenger side on the rear receiver hitch frame.
8.
Remove the brake line from the clamp locations under the vehicle frame and floorboard.
9.
Remove the brake lines that are toward the rear of the vehicle on the passenger side. See following NOTE.
NOTE: Tie a heavy nylon string to the flare-nut end of the brake line before removal. Allow the string to travel with the
brake line until it clears the rear of the vehicle. During replacement, tie the flare-nut end of the new brake line
to the nylon string and use it to pull the new brake line into position and to the master cylinder.
REAR BRAKE LINE INSTALLATION
1.
Feed a new brake line from the rear of the vehicle and position it in line with the frame clamps and up to the
master cylinder. See following NOTE.
NOTE: If a heavy nylon string was used to remove the previous rear brake line, tie the string to the flare-nut end of the
new brake line. Use the string to pull the new brake line into position and to the master cylinder.
2.
Carefully install the flared end of the brake line into the master cylinder and tighten to 11 in-lb (15 N·m).
3.
Secure the brake lines to the clamp and grommet locations.
4.
Secure the brake lines, banjo bolts, and new copper washers to each rear wheel caliper. Tighten the hardware to
13 ft-lb (18 N·m). See following NOTE and CAUTION.
NOTE: Position the brake line perpendicular to the caliper assembly and pointing directly toward the base bracket
on the shock absorber.
CAUTION
• The banjo bolts are metric. Use only metric thread replacements.
5.
Fill the reservoir of the master cylinder and bleed the hydraulic system. See Bleeding the Hydraulic Brake
System on page 6-15.
6.
Perform all of the brake system inspections. See Brake System Inspection on page 6-1.
2014 Carryall 295/XRT 1550 Maintenance and Service Manual
Hydraulic Line Replacement
6
Page 6-13
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