| CitiCar Disc Brake assemblies are obsolete; superseded with a
conversion kit to drum brakes in the early 1980's. The primary cause of problems appears
to be faulty maintenance; the brake fluid MUST be changed anually. Read, understand and
follow the recommendations contained on this page.
Besides the parts contained in the Nu-Kar disc brake rebuild kits,
you will need:
- 7/16" combination wrench (box/open end) -2
- 3/8" box end wrench -1
- New can of approved brake fluid -1
- 0000 steel wool
- Brake cleaning fluid -1 can
- Jack and jack stand
Chock rear wheels, raise front wheels and place jack stand under the
axle.
Remove wheel.
Remove the caliper brake tube from the flexible line.
Remove the two 7/16" bolts from the top of the caliper. DO NOT
hang the caliper assembly from the flexible brake line. This is not possible if you did
the previous step!
Remove the caliper assembly to suitable work space.
Disassemble caliper. Use care if compressed air is used to eject
puck. Clean all metal parts with brake cleaner. DO NOT use a common brake hone on the
cylinder. Tapering WILL occur and destroy the integrity of the brake. Gently polish any
corrosion away with the 0000 steel wool. Wash the parts again. Replace the "0"
ring on the puck, and wipe with clean brake fluid. Return the puck to the cylinder
("0" ring side goes in first), pushing it all the way to the bottom. Replace the
springs with the new stainless steel ones found in the repair kit. (Springs are provided
for both modifications - see "CitiCar/CommutaCar Repair Manual" for
specifications). Return assembly to the wheel and ensure it works freely in the guides.
Use a dry lubricant only on the guides and bushings. Reinstall assembly.
When all the brakes have been reworked, bleed the system. Start with
the rear passenger side, the rear driver's side, the front passenger's side and finally
the driver's front. DO NOT let the master cylinder run dry. Be sure each brake is bled
until the fluid coming out is clean. Brakes should be bled annually.
IMPORTANT: DOT 3-4 Brake
fluids are the only recommended fluids for CitiCars and ComutaCars. Dot 5, which is
silicone based may destroy some of the seals in the brake system. Dot 3 & 4 Brake
Fluids contain corrosion inhibitors to prevent any moisture that collects in the system
from causing problems. Unfortunately these inhibitors brake down over time, therefore, it
is recommended to change the fluid annually.
Copyright © 1997 Assembled Products, Inc.
This page was created June, 1997
Most recent revision
November 09, 2006 |
