Rear Brake Hose Installation; Master Cylinder And Bell Crank Replacement; Bell Crank Removal; Bell Crank Installation - Pioneer 1200 Maintenance Service Manual

MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS

REAR BRAKE HOSE INSTALLATION

1. Install brake hose (9) through the oval-shaped hole in the vehicle I-beam, and install the horseshoe clip
(12) that secures the brake hose to the I-beam frame (Figure 6-20, Page 6-25 or Figure 6-21,
Page 6-28).
2. Attach the flare nut fitting on the brake hose (9) to the wheel cylinder (Figure 6-17, Page 6-18) and
tighten to 11 ft-lb (14.9 N·m).
3. Install the rear brake line (10 or 11) to the rear hose (9) at the I-beam of the vehicle frame (Figure 6-20,
Page 6-25 or Figure 6-21, Page 6-28). Tighten to 11 ft-lb (14.9 N·m).
4. Repeat steps 1 through 3 for the opposite rear brake hose if necessary.
5. Fill the reservoir of the master cylinder and bleed the hydraulic system. See Bleeding the Hydraulic
Brake System on page 6-31.
6. Perform all of the brake system inspections. See Brake System Inspection on page 6-1.

MASTER CYLINDER AND BELL CRANK REPLACEMENT

See General Warning, Section 1, Page 1-1.

BELL CRANK REMOVAL

1. Chock the wheels and release the park brake and access the master cylinder bell crank.
2. Remove the brake rod clevis bolt (6) and clevis (16) from the bell crank assembly (13) (Figure 6-22,
Page 6-30).
3. Remove the spring (18) from the bell crank (13) and master cylinder mounting bracket (19).
4. Remove the push rod clevis bolt (20) and lock nut (21) from the bell crank (13).
5. Remove the bell crank bolt (9) and nylon lock nut (11) from the master cylinder mounting bracket (19) and
remove bell crank (13) and two centering spacers (12).
6. Inspect the needle bearing (14) and the inner race (15) for damage or wear and replace if necessary
(Figure 6-22, Page 6-30).
NOTE: The needle bearing (14) is press fitted to the bell crank. If replacement is necessary, the bearing
must be pressed out and replaced (Figure 6-22, Page 6-30).

BELL CRANK INSTALLATION

1. Install the bell crank bolt (9) through the two centering spacers (12) and bell crank inner bearing race (15)
and tighten nut (11) to 25 ft-lb (40 N·m) (Figure 6-22, Page 6-30).
2. Install bolt (20) through push rod (3), bell crank (13), and nylon lock nut (21) and tighten to 14 ft-lb (19
N·m).
3. Install brake rod clevis bolt (6) through clevis (16) and bell crank (13) and tighten to 19 ft-lb (25.8 N·m).
4. Install spring (18).
5. Adjust the brake pedal as instructed. See Brake Pedal Adjustment, Section 5, Page 5-3.
6. Perform all of the brake system inspections. See Brake System Inspection on page 6-1.
2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual
Master Cylinder And Bell Crank Replacement
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