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Final Drive/Brake System
Phantom Brake Caliper Removal
SILENCER BRACKET
600 RUSH DC-CFI-4 MODELS ONLY
ALL OTHER PHANTOM=WASHERS
1. Remove the two caliper bolts that hold the caliper and
silencer bracket to the chaincase.
NOTE: DC-CFI-2 models with Phantom calipers do
not feature silencer bracket. Washers are installed in
its place.
2. Remove the caliper from the chaincase. Tie the
caliper to the overstructure. Do not allow the brake
caliper to hang from the brake hose.
Phantom Brake Caliper Installation
1. Apply Loctite® 242™ and replace caliper bolts, and
silencer bracket or washers if equipped. Torque bolts
to specification.
Caliper Bolts: 40 ft-lbs (54 Nm)
2. Place the brake line on the caliper in the same
orientation as it was before it was removed.
3. Clean the threads of the banjo bolt and the threads in
the caliper.
4. Follow Brake Line Replacement. See "Brake Line
Replacement" on page 5.24.
5. Install banjo bolt into the caliper and torque it to
specification.
6. Bleed the brakes. See "Brake Fluid Replacement &
Bleeding" on page 5.22.
7. Test brake system prior to returning vehicle to service.
5.26
= T
Phantom Brake Caliper Piston and Seal
Replacement
CALIPER BORE PLUG
DO NOT PUSH OR MOVE!
PISTON SEAL
CAUTION
NEVER RE-USE PISTON SEALS. ALWAYS REPLACE
WITH NEW PARTS.
DO NOT ATTEMPT TO SAND OR POLISH A CALIPER
PISTON.
1. Remove the brake hose from the caliper. Drain the
brake fluid into a jar or suitable container.
2. Rotate and remove the brake pad retaining pin and
then remove the brake pads. Remove the caliper from
the chaincase.
3. Hold the caliper over the brake fluid jar and then push
the pistons back into the caliper. This will push the
brake fluid in the caliper out of the brake hose banjo
fitting hole.
CAUTION
NEVER RE-USE BRAKE FLUID. USED BRAKE FLUID
MAY CONTAIN AIR BUBBLES. ALWAYS USE NEW
BRAKE FLUID FROM AN UNOPENED CONTAINER.
4. Clamp the end of a 1/4" thick 2" x 10" piece of steel to
the workbench. Allow the piece of steel to hang off of
the bench by 4 - 5".
PISTON SEAL
PISTONS
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