JAC HFC4DA1-2C engine. Instruction — part 34

BR

BR

BR

BR Brake

Brake

Brake

Brake System

System

System

System

- 51-

Removal/Installation

Removal/Installation

Removal/Installation

Removal/Installation

Installation
1.

Install the wheel hub onto the brake disc.
Bend the lock lug on the set bolt up.

Caution:

Caution:

Caution:

Caution:

The left hand side bearing adjusting nut is of left
hand thread.

2.

Reinstall the hub bearing:

�

Reinstall the washer and brake disc assembly,
as well as the outer bearing.

�

Reinstall the wheel bearing adjusting nut.

3.

Reinstall the brake caliper.

4.

Install the brake hose onto the shock absorber.

5.

Check the front disc runout as required.

6.

Set the axial clearance of wheel bearing:

�

Tighten the adjusting nut of wheel bearing and
rotate the wheel at the same time to make it
closely fitted against the bearing.

�

Rotate the adjusting nut by 180 degree and
shake the wheel to make the hang properly
fitted.

�

Push and pull the wheel horizontally to check
the bearing axial clearance. If no clearance
can be felt, adjust the adjusting nut to make
the axial clearance within 0.002~0.05mm.

7.

Use new split pin to reinstall the nut lock piece and
the dust cover.

8.

Reinstall the wheel.

9.

Lower the vehicle.

BR

BR

BR

BR Brake

Brake

Brake

Brake System

System

System

System

- 52 -

Replacement

Replacement

Replacement

Replacement of

of

of

of front

front

front

front brake

brake

brake

brake disc

disc

disc

disc

Removal
1.

Have the vehicle lifted to remove the front wheel.

2.

Remove the plastic cap of brake caliper sliding pin.

3.

Make the brake disc exposed:

�

Remove the guide pin bolt of brake caliper.

�

Upturn the brake caliper.

Note:

Note:

Note:

Note:

The ablated or damaged piston bush should be
replaced.

4.

Remove the inner/outer brake pad.

Note:

Note:

Note:

Note:

Resetting of wheel cylinder piston shall make the
brake fluid returned to the fluid reservoir of master
cylinder.

5.

Push the wheel cylinder piston carefully to the
original position.

BR

BR

BR

BR Brake

Brake

Brake

Brake System

System

System

System

- 53-

Removal/Installation

Removal/Installation

Removal/Installation

Removal/Installation

6.

During the installation of new brake lining, please
remove the snap ring of brake lining from the brake
caliper.

7.

Clear any dirt within the mounting areas.

Installation
1.

Install new snap ring onto new brake lining.

2.

Check if two brake linings are of the same type.

3.

During the installation of new brake lining, please
remove the interleaving paper from the acoustic
lining.

4.

Reinstall inner/outer brake lining.

5.

Reinstall the brake caliper assembly:

�

Install the brake caliper assembly.

�

Install the guide pin bolt of brake caliper.

�

Install the plastic cap of brake caliper guide
pin.

6.

Adjust the slider of brake plate.

7.

Reinstall the wheel and lower the vehicle.

8.

Check the brake fluid level of master cylinder. If
insufficient, please add brake fluid to the standard
position.

BR

BR

BR

BR Brake

Brake

Brake

Brake System

System

System

System

- 54 -

Removal/Installation

Removal/Installation

Removal/Installation

Removal/Installation

Brake

Brake

Brake

Brake caliper

caliper

caliper

caliper assembly

assembly

assembly

assembly

Removal
1.

Have the vehicle lifted and remove the front wheel.

Note:

Note:

Note:

Note:

Clamp the brake hose with SST in order to avoid
damage of brake hose.

2.

Clamp the brake hose.

3.

Remove the brake hose from the caliper.
Put on the seal plug to avoid excessive leak of
brake fluid or contamination of dust.

Note:

Note:

Note:

Note:

Loosen the upper mounting bolt of caliper until the
brake caliper can be removed.

4.

Remove the brake caliper assembly.

BR

BR

BR

BR Brake

Brake

Brake

Brake System

System

System

System

- 55-

Removal/Installation

Removal/Installation

Removal/Installation

Removal/Installation

Installation
1.

Reinstall the brake caliper.

2.

Connect the brake hose to the brake caliper.

3.

Fix the brake hose onto the shock absorber.

4.

Bleed air out of brake line in accordance with
specification.

5.

Install the wheel and lower the vehicle. Depress the
brake pedal to adjust brake clearance.

BR

BR

BR

BR Brake

Brake

Brake

Brake System

System

System

System

- 56 -

Removal/installation

Removal/installation

Removal/installation

Removal/installation of

of

of

of rear

rear

rear

rear wheel

wheel

wheel

wheel brake

brake

brake

brake shoe

shoe

shoe

shoe

Removal
1.

Release the parking brake lever, have the vehicle
lifted and remove the rear wheel.

2.

Remove the automatic regulator.

3.

Mark properly on the wheel hub and rim for
removal of hub.

Caution:

Caution:

Caution:

Caution:

Don’t make the axle casing oil seal damaged.

4.

Remove the axle shaft.

5.

Remove flange nuts.

6.

Remove the flange.

BR

BR

BR

BR Brake

Brake

Brake

Brake System

System

System

System

- 57-

Removal/Installation

Removal/Installation

Removal/Installation

Removal/Installation

7.

Remove the leading shoe:

�

Remove the lock pin and its spring cap.

�

Remove the brake shoe lower end from the
support.

�

Loosen the lower return spring.

�

Remove the brake shoe upper end from the
wheel cylinder.

�

Loosen the upper return spring.

8.

Remove the trailing shoe:

�

Remove the lock pin and its spring cap.

�

Remove the trailing shoe from the wheel
cylinder and support.

�

Disconnect the parking brake cable.

9.

Disassemble the leading shoe:

�

Remove retainer ring from the inside of brake
shoe.

�

Remove washer and spring from the fulcrum
pin.

�

Remove spring and retainer ring from the
ratchet.

�

Remove ratchet and washer from brake shoe.

10. Disassemble the trailing shoe:

�

Remove return spring and strut from parking
brake lever and brake shoe.

�

Remove retainer ring, fulcrum pin, washer and
tie rod from brake shoe.

BR

BR

BR

BR Brake

Brake

Brake

Brake System

System

System

System

- 58 -

Removal/Installation

Removal/Installation

Removal/Installation

Removal/Installation

Installation
1.

Clean the support plate and apply ABS fluid onto
the bonding point between brake bottom plate and
brake shoe.

2.

Assemble the trailing shoe.
Apply grease onto parking brake lever and brake
shoe.

3.

Reconnect the parking brake cable to the lever.

4.

Reinstall the trailing shoe.

5.

Assemble the leading shoe.
Apply grease between the adjusting ratchet and the
fulcrum pin.

6.

Reinstall the leading shoe.

7.

Install the upper/lower return spring of brake shoe.

8.

Install the brake shoe lock pin, and the fixed pin
and clip of spring.

Note:

Note:

Note:

Note:

Please don’t make the brake lining contaminated
by any oil or grease. If any, please wipe it clean
with sand paper.

9.

Reinstall the flange.

Note:

Note:

Note:

Note:

The annular mark on the left side flange nut of
vehicle indicates the nut is of left hand thread.

10. Retighten the flange nut.

Caution:

Caution:

Caution:

Caution:

Don’t make the half axle oil seal damaged.

11. Reinstall the half axle:

�

Install the spacer.

�

Install a new O-ring.

�

Install a new oil seal.

�

Install the half axle.

12. Reinstall the brake drum.
13. Reinstall the tire and lower the vehicle.

BR

BR

BR

BR Brake

Brake

Brake

Brake System

System

System

System

- 59-

Parking

Parking

Parking

Parking brake

brake

brake

brake adjustment

adjustment

adjustment

adjustment

1.

Release the parking brake and have the vehicle
lifted.

2.

Release the parking brake regulator.

�

Loosen the lock nut.

�

Rotate the regulator.

3.

Depress the brake pedal to ensure proper automatic
regulation.

4.

Pull up the parking brake lever until it gets stuck at
the 3

rd

tooth.

Note:

Note:

Note:

Note:

Ensure thread length on both sides are the same
and the thread can be observed through the hole of
regulator.

Note:

Note:

Note:

Note:

The parking brake lever can be pulled up by four to
six teeth after the last regulation is finished.

5.

Tighten the parking brake adjusting nut:

�

Tighten the adjusting nut by hand.

�

Tighten the adjusting nut.

BR

BR

BR

BR Brake

Brake

Brake

Brake System

System

System

System

- 60 -

Removal/installation

Removal/installation

Removal/installation

Removal/installation of

of

of

of parking

parking

parking

parking brake

brake

brake

brake lever

lever

lever

lever

Removal
1.

Loosen the parking brake lever.

2.

Remove the wavy dust shield of parking brake.

3.

Remove the parking brake lever assembly:

�

Remove the spring clip and the clevis pin for
fixing cable.

�

Remove the mounting bolts from parking
brake lever.

Installation
4.

Reinstall the parking brake assembly:

�

Tighten the mounting bolts of parking brake
lever.

�

Install the spring clip and the clevis pin for
fixing the main cable.

�

Install the wavy dust shield of parking brake.

BR

BR

BR

BR Brake

Brake

Brake

Brake System

System

System

System

- 61-

Removal/installation

Removal/installation

Removal/installation

Removal/installation of

of

of

of parking

parking

parking

parking brake

brake

brake

brake cable

cable

cable

cable

Removal
1.

Loosen the parking brake lever.

2.

Remove the spring clip and the clevis pin from the
main cable and remove the cable from the parking
brake lever.

3.

Separate the main cable from the equalizer:

�

Remove the spring clip and the clevis pin.

�

Remove the return spring from the equalizer.

4.

Remove the main cable.

Installation

1.

Reinstall all parts in the reverse order of removal.

2.

Regulate the parking brake in accordance with
specification when necessary.

BR

BR

BR

BR Brake

Brake

Brake

Brake System

System

System

System

- 62 -

Replacement

Replacement

Replacement

Replacement of

of

of

of parking

parking

parking

parking brake

brake

brake

brake cable

cable

cable

cable

Removal:

1.

Loosen the parking brake lever.

2.

Remove the main cable from the equalizer:

�

Remove the spring clip and the clevis pin.

�

Remove the return spring from the equalizer.

3.

Remove the rear brake drum.

4.

Remove the rear cable from the brake shoe control
lever.

5.

Remove the rear cable from the brake bottom plate.

6.

Remove the cable from the bracket hook.

Installation

1.

Reinstall all parts in the reverse order of removal.

2.

Regulate the parking brake in accordance with
specification when necessary.

BR

BR

BR

BR Brake

Brake

Brake

Brake System

System

System

System

- 63-

Removal/installation

Removal/installation

Removal/installation

Removal/installation of

of

of

of brake

brake

brake

brake pedal

pedal

pedal

pedal

Removal
1.

Disconnect the negative cable of battery.

2.

Remove the clevis pin and spring clip from the
vacuum booster control rod of brake pedal.

3.

Remove the brake switch:

�

Disconnect the harness connector.

�

Remove the brake switch.

4.

Remove the brake and clutch pedal spider clip from
the pedal bracket.

BR

BR

BR

BR Brake

Brake

Brake

Brake System

System

System

System

- 64 -

Removal/Installation

Removal/Installation

Removal/Installation

Removal/Installation

5.

Remove the brake pedal:

�

Push the spider to the direction of clutch
pedal.

�

Remove the brake pedal.

6.

Remove the pedal bushing and spring:

�

Remove the pedal bushing.

�

Remove the spring.

Installation

1.

Reinstall all parts in the reverse order of removal.

2.

Reinstall and regulate the brake switch:

�

Screw in the switch.

�

Reconnect the harness connector.

BR

BR

BR

BR Brake

Brake

Brake

Brake System

System

System

System

- 65-

Removal/installation

Removal/installation

Removal/installation

Removal/installation of

of

of

of brake

brake

brake

brake master

master

master

master cylinder

cylinder

cylinder

cylinder

Caution:

Caution:

Caution:

Caution:

Don’t the make the brake fluid splashing onto the
paint surface. In case of any, please wash the
surface with clean water immediately.

Removal
1.

Disconnect the negative cable of battery.

2.

Remove the brake fluid reservoir cap:

�

Disconnect the fluid level alarm harness
connector.

�

Remove the fluid reservoir cap.

3.

Remove the clutch master cylinder pipe and drain
the brake fluid out of the master cylinder fluid
reservoir.

4.

Remove the brake line from brake master cylinder
and

block

the

pipe

with

plug

to

avoid

contamination by dirt.

Caution:

Caution:

Caution:

Caution:

Please ensure the air in vacuum booster is fully
bled before the removal of brake master cylinder.
Remove the vacuum pipe from the booster for air
bleeding.

5.

Remove the master cylinder.

6.

Install

it

in

the

reverse

order of

removal.

Remember

to

perform

air

bleeding

after

installation. Please bleed air out from system in
accordance with specification.

BR

BR

BR

BR Brake

Brake

Brake

Brake System

System

System

System

- 66 -

Removal/installation

Removal/installation

Removal/installation

Removal/installation of

of

of

of vacuum

vacuum

vacuum

vacuum pump

pump

pump

pump

Caution:

Caution:

Caution:

Caution:

Don’t the make the brake fluid splashing onto the
paint surface. In case of any, please wash the
surface with clean water immediately.

Removal

1.

Disconnect the negative cable of battery.

2.

Remove the vacuum pipe from the pump.

Note:

Note:

Note:

Note:

Plug the pipe orifice to avoid contamination by
dirt.

3.

Remove the oil inlet pipe and the oil return pipe
from the pump.

4.

Remove the vacuum pump.