MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Hydraulic Line and Hose Replacement
Page 6-26 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual
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Rear Brake Line Removal, Continued:
2.3. Place a pan below the vehicle to collect the brake fluid.
2.4. Use a 3/8-inch flare nut wrench to remove rear brake line (15) from the master cylinder
(Figure 6-21, Page 6-28).
2.5. Use a 3/8-inch flare nut wrench and remove rear brake line (15) from the brake tee (17).
2.6. Remove rear brake line (10 or 11) from the brake tee.
2.7. Remove rear brake line (10 or 11) from the brake hose at the I-beam of the vehicle frame.
2.8. Repeat steps 2.6 and 2.7 for the opposite rear brake line if necessary.
2.9. Remove the bolt (18) from the brake tee (17) and remove the tee from the vehicle frame.
REAR BRAKE LINE INSTALLATION
1. Pioneer 1200:
1.1. Install brake line (10 or 11) to rear brake hose at the I-beam of the vehicle frame and tighten to 11
ft-lb (14.9 N·m) (Figure 6-20, Page 6-25).
1.2. Install the opposite end of the brake line to the master cylinder and tighten the flare nut fitting to 11
ft-lb (14.9 N·m).
1.3. Repeat steps 1.1 and 1.2 for the opposite rear brake line if necessary.
1.4. Fill the reservoir of the master cylinder and bleed the hydraulic system. See Bleeding the Hydrau-
lic Brake System on page 6-31.
1.5. Perform all of the brake system inspections. See Brake System Inspection on page 6-1.
2. Pioneer 1200SE:
2.1. Install brake tee (17) to vehicle frame plate using hex-head 1/4-20 x 3/4-inch bolt (18) and tighten
to 65 in-lb (7.345 N·m)(Figure 6-21, Page 6-28).
2.2. Install brake line (10 or 11) to rear brake hose at the I-beam of the vehicle frame and tighten to 11
ft-lb (14.9 N·m).
2.3. Install the opposite end of the brake line to the brake tee (17) and tighten to 11 ft-lb (14.9 N·m).
2.4. Repeat steps 2.2 and 2.3 for the opposite rear brake line if necessary.
2.5. Install rear brake line (15) to the brake tee (17) and tighten to 11 ft-lb (14.9 N·m).
2.6. Install opposite end of the brake line (15) to the master cylinder and tighten to 11 ft-lb (14.9 N·m).
2.7. Fill the reservoir of the master cylinder and bleed the hydraulic system. See Bleeding the Hydrau-
lic Brake System on page 6-31.
2.8. Perform all of the brake system inspections. See Brake System Inspection on page 6-1.
REAR BRAKE HOSE REMOVAL
1. Chock the front wheels, release the park brake, and lift the rear of the vehicle with a chain hoist or floor
jack. See WARNING "Lift only one end..." in General Warning, Section 1, Page 1-2.
2. Place jack stands under the rear axle tubes and lower onto stands. See Figure 5-2, Section 5,
Page 5-3.
3. Place a pan below the vehicle to collect the brake fluid.
4. Use a 3/8-inch flare nut wrench to remove the brake hose from the wheel cylinder (Figure 6-17,
Page 6-18).
5. Use a 3/8-inch flare nut wrench to remove the rear brake line (10 or 11) from the rear brake hose at the
I-beam of the vehicle frame (Figure 6-20, Page 6-25 or Figure 6-21, Page 6-28).
6. Remove the horseshoe clip (12) that secures the rear brake hose (9) to the I-beam frame and remove
brake hose (9) through the oval-shaped hole in the vehicle I-beam.
7. Repeat steps 4 through 6 for the opposite rear brake hose if necessary.
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