Argo Service Manual Cover 05-06
Contents
1. 2 Back off the locking jam nut at the cam and apply a small amount of blue 242 LOCTITE to the threads between the jam nut and main adjustment nut 3 Snug the locking jam nut up against main adjustment locknut Photo BR 58 4 Back off the nut on the rear bolt to free it up just enough to allow it to be turned by hand Photo BR 59 5 Slowly back off the front jam nut and adjustment nut until movement is felt in the caliper 6 Place a 010 feeler gauge between the left hand brake caliper and the brake disc while pushing the right caliper half against the brake disc Photo BR 60 j j Fa Ths y E d X h j gt 45 a l be Jd r PE i i f ey A l fa e gt i ik i J l 7 rs aa vr 4 y Mi i Ontario Drive amp Gear Limited BR 33 www odg com PH 519 662 2840 FAX 519 662 2421 ales Brake System Argo Service Manual 7 Using two opened end wrenches tighten the jam nut against the adjust ment nut 8 Recheck the clearance one more time and adjust if necessary 9 Install return spring amp flat washer to adjustment rod and loosely start the locknut to the end Photo BR 61 10 Perform the servicing procedure Installing the Firewall in section VB Steering Lever Adjustment Adjust the steering levers when m steering levers travel more than 18 cm 7 from the dash to apply the brakes m the levers are not parallel when the brakes are applied or m the brake adjustment nuts have been removed duri2. Using a 0 004 feeler gauge or a piece of regular photo copy paper such as a piece cut from these instructions slip it between the emergency parking brake pad and brake disc Ensure that you push the opposite side pad up against the brake disc before setting this gap Slowly hand tighten the castle nut until the feeler gauge or piece of paper becomes snug between the pad and brake disc Back off the castle just enough for a new cotter pin to be installed The feeler gauge or piece of paper should pull out at this point with just the slightest bit of resistance Ontario Drive amp Gear Phone 519 662 2840 Fax 519 662 2421 10 11 12 Recheck the cable between the equalizer flat bar and the brake lever cams to ensure 1t 1s just on the verge of engag ing the calipers Lock down jam nuts Check to ensure that the brakes are NOT engaged when the Brake Lever is in the down amp off position Check for drag by driving without activating any brakes for about 100 feet Stop and check for heat on the brake discs They should both be cool or no hotter than the beginning of the test Adjust if necessary Check the effectiveness of the parking brake by parking the Argo on the steepest hill encountered and by loading to it s maximum working load The parking brake should hold the Argo from moving Check the effectiveness of the emergency brake by acti vating it while coasting down a slight grade The Argo should
3. Vehicles Affected AVENGER and FRONTIER BR 12A Ontario Drive amp Gear Phone 519 662 2840 Fax 519 662 2421 OWond com Instructions NOTE Both left and righthand side emergency parking brake caliper pads should be changed in pairs Do not attempt to just replace one side 1 Locate the emergency parking brake caliper attached to the main brake caliper Figure 1 Left hand side example Figure I Locate Caliper 2 Locate the castle nut at the brake cam lever and remove the cotter pin and castle nut Figure 2 Figure 2 Remove Cotter Pin 3 Using both hands remove the brake lever assembly from the Brake Housing Live Side and disconnect spring Fig ure 3 BR 13A Figure 3 Remove Brake Lever 4 Remove the two 2 mounting bolts holding the caliper assembly together Figure 4 Figure 4 Remove Mounting Bolts Split and remove the caliper assembly Figure 5 Take note of all spacers shims and washers within the assembly Refer to your illustrated parts list in your Argo Parts manual for all locations of these components Locate the 850 84 Dead Side Brake Housing and remove the screw securing the brake puck Remove the brake puck and discard Figure 6 Locate the Live Side Brake Housing and turn upside down to remove 2nd brake pad from the housing cavity Please note that there is also a washer placed beneath the brake pad Ontario Drive amp Gear Phone 519 662 28
4. through the fluid inlet hole Ontario Drive amp Gear Limited BR 16 www odg com PH 519 662 2840 FAX 519 662 2421 NOTE Models manufactured after May 25 2000 from S N CB17145 RB17120 BF11608 and SN11630 have a tapered spring which attaches to the end of the piston Models prior to this had a shorter spring which did not attach to the piston The newer spring is fully exchangeable with the older style but should be replaced as a set 3 Slide the primary and secondary seals off the piston Discard these old seals A CAUTION Do not scratch the piston when removing the seals 4 Clean all components with alcohol or a mild soap solution Use compressed air to blow out the master cylinder castings This will free up any dirt or other contami nants you could not reach with the cloth Master Cylinder Servicing amp Inspection NOTE Use only genuine ARGO parts 1 Thoroughly inspect all components of the master cylinder assembly and replace any worn cracked or broken parts 2 Inspect the condition of the piston Replace the piston immediately if it is Scratched Pitted rusted scored in any way Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 BR 17 SOWrklcm Brake System Argo Service Manual 2 a Inspect the condition of the master cylinder housing Replace immediately if the piston bore is scratched pitted or rusted the casing is cracke
5. Biya A CAUTION When reassembling the caliper work with clean hands tools and parts Perform the reassembly on a clean neat surface Dirt or contaminants on component parts will cause a reduction in brake efficiency and may damage the brake components 3 Place the caliper castings on a clean workbench so that the interior is fac ing up Photo BR 13 4 Insert the rubber seals into each half of the caliper casting Photo BR 14 A CAUTION Do not scratch or tear the seals during installation Any damaged seal must be replaced immediately 5 Insert the pistons so that the cavity side is facing up 6 Place the one half caliper into the aluminum jawed vise being careful not to damage it by overtightening it Locate the oil journal which requires the small O ring Place the O ring over the hole making sure that the flat edge of the ring 1s facing down Photo BR I5 7 Place the other half caliper to the one secured in the vise making sure that the oil journal of the top half is aligned with the previously installed O ring in the lower half Photo BR 16 Ontario Drive amp Gear Limited BR 13 www odg com PH 519 662 2840 FAX 519 662 2421 j Brake System Argo Service Manual 8 Reinstall the socket head bolts which hold the caliper assembly together Use blue LOCTITE on the threads of the fasteners Torque the bolts to the specified torque Photo BR 17 9 Place the check ball and bleeding s
6. Mechanical Brake Callipet cccccccsssssssssssssssscseeees BR 33 Steering Lever Adjustment Mechanical cccccccccssssssssssssccceesees BR 34 Holding Brake Adjustment eeeececcsccsssssssccccccecescossssssssesceeeesssssssssoe BR 34 Brake Disc Inspection s ssesesseseccseccsecceccescccoscsscecosccsecoosccscesossssccocsecesee BR 35 Removing a Brake DisC eeeccssccccccssecccecsssececccsecceccsssececcsssececcsssececcssoe BR 36 Installing the Brake DiSC ssseceeccssecccccseccccccseccccccsscccecsssececcsssececcssseeeo BR 39 Parking Brake Assembly CE Kit Models Only sccsccsssssees BR 40 Brake Cooling SYStCiilsicssvesissdeccscevessszavecnscaessesvivicedenssseesvesvesessnseesivesssees BR 46 Dissasembling the Steering Column Brake Assembly Moto Cross Style Supplement Page ccccccccccsssssssssccccccccsssees BR 1A Parking Emergency Brake System Avenger Frontier 000 BR 12A Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 BR 2 Sweden General Instructions Always refer to the correct PARTS MANUAL in accordance with the specific model and serial number indicated on the serial tag plate of your vehicle This is essential to locating and ordering the correct components that were used during that particular manufacturing period when the ARGO was built It is also very helpful using the illustrations to clearly see and define the component
7. Steering Column Assembly Photo ST 5 Insert Shim between Fr Collar and Welded Stop On all models manufactured from C22453 R22452 B14700 A14743 N14708 1 Remove the 3 fasteners securing the 612 117 steering column assembly to the transmission Photo ST 18A You must do this in order for the steering shaft to clear the brake calipers below when slipping it from the steering column IMPORTANT Be aware of the 108 08 Flat Washer Spacers used between the Steering Column Frame Assembly and the transmission mounting bosses 11 Slip the shaft from the column 8 Disassemble the steering shaft as follows On Avenger Models Only Prior to V22441 1 Place the Steering Shaft on a clean work bench and remove the 4 roll pins Photo ST 6 Slide each steering arm and centering spring from the shaft NOTE 1 Retaining Ring is located between the two Steering Arms Vehicles manufactured from V22441 C22453 R22452 B14700 A14743 N14708 1 Remove the 2 Spring Pins and Steering Arms from the Steering Shaft Photo ST 7 A Retaining Ring is located between the two steering arms Ontario Drive amp Gear Limited BRA www odg com PH 519 662 2840 FAX 519 662 2421 a RNY as 519 662 2840 519 66 GV Argo Service Manual Brake Steering System Reassembling Steering Column Avenger Models Only Prior to V22441 i Install the Spring Pin into the Steering Shaft at the 4th hole from the end Photo ST 8 The roll pin shou
8. come to a controlled stop without pulling left or right Re adjust the brakes if necessary The emergency parking brake should be checked for proper adjustment every 25 hours Note Oil on the brake disc caused by improper chain oiling will temporarily reduce the effectiveness of the brakes BR 18A Ontario Drive amp Gear Phone 519 662 2840 Fax 519 662 2421
9. from the brake travel adjustment rod BR 36 2 Remove the front floor pan and the firewall See servicing procedure Removing the firewall in section VB of this service guide 3 Locate the brake caliper assemblies Photo BR 37 Ontario Drive amp Gear Limited BR 27 PH 519 662 2840 FAX 519 662 2421 j Brake System Argo Service Manual 4 Remove all locknuts and jam nuts from the 2 bolts that secure the two halves of the mechanical calipers together at the power pack frame Photo BR 38 5 Remove the brake cam assembly and flat washer Photo BR 39 6 Remove both mounting bolts and separate the calipers from the power pack frame Collect the 2 compression springs that are used in each side of the caliper Photo BR 40 NOTE If you are disassembling the right hand steering caliper assembly you will need to remove the parking brake lever and spring from the rear caliper bolt as well Photo BR 41 Ontario Drive amp Gear Limited BR 28 www odg com PH 519 662 2840 FAX 519 662 2421 Baan Leam IMPORTANT The cam side half caliper houses 2 small steel bearing balls These are installed to 2 bearing seats within the casting These steel balls should be checked for any wear or deformity Also check the inside of the brake cam where it comes into contact with these steel ball bearings If there is any wear noticed such as tracking grooves replace the brake cam Any wear grooves in the cam will affec
10. from the vise and separate the 2 halves Photo BR 10 7 Lift the piston seals and the O ring from the caliper halves and discard Photo BR 11 Ontario Drive amp Gear Limited BR 11 www odg com PH 519 662 2840 FAX 519 662 2421 j a Brake System Argo Service Manual 8 Remove the bleed screws and check the steel ball from the caliper casting Photo BR 12 9 Clean all components in a varsol bath then a mild soap solution Use com pressed air to blow out the caliper cast ings This will free up any dirt or other contaminants you could not reach with the cloth 10 Wipe all components with a lint free cloth or use compressed air to dry 11 Thoroughly inspect all the components Replace any worn cracked or broken or missing parts 12 Inspect both piston chambers for any pitting scratching scarring or rust Replace pistons with new or the entire caliper assembly if necessary Hydraulic Brake Caliper Reassembly 1 Begin with all the components on a clean surface 2 Lubricate all component parts with fresh DOT 5 Silicon Brake Fluid A WARNING Do not allow brake fluid to contact your eyes clothes or painted surfaces Brake fluid is extremely corrosive and can cause severe personal injury Wear protective eye goggles gloves and clothing If brake fluid contacts your eyes consult a physician immediately Ontario Drive amp Gear Limited BR 12 www odg com PH 519 662 2840 FAX 519 662 2421
11. of an improperly adjusted emergency parking brake is a serious hazard and could lead to vehicle damage or personal injury The hand brake lever should be adjusted such that when pulled up firmly it is capable of holding the vehicle from rolling on a grade It should also ensure a good braking response when applied to stop the vehicle during normal operation Figure 15 Dowel Pins BR 16A Ontario Drive Gear Phone 519 662 2840 Fax 519 662 2421 A CAUTION If the emergency parking brake system is adjusted too tight when the lever is in the down position overheat ing of the brake system will occur due to drag between brake pads and brake discs Adjusting the Emergency Parking Brake L Ensure the parking brake lever is fully down 2 Locate the 850 72 Parking Brake Adjustment Bracket at tached to the top of the transmission Figure 7 20 Adjust to remove any slack in the cable that may be present be tween the brake lever and the brake cams at the emer gency parking brake calipers This may require physically pulling down on the equalizer flat bar to ensure all slack is eliminated See Figure 7 21 BR 17A Figure 7 21 Equalizer Flat Bar Adjust the cable at the transmission until the cam levers are actually starting to pre load the return springs and the cam lever actuation pin on the caliper is centered in the v grove of the cam Figure 7 22 a de mee A E Figure 7 22 V Groove of the Cam
12. pads or abnormal use of the vehicle can cause serious damage to the brake discs Inspect the brake discs for the condition listed in the chart below and perform the recommended servicing procedures Brake Disc Condition Corrective Action Servicing Procedure Rust or Pitting Replace Immediately 1 Brake Disc Removal Bends or Cracks 2 Brake Disc Installation Scratches or Scoring Broken or worn Sprocket teeth Glazing 1 Brake Disc Removal Oil or Grease Con 2 Brake Disc Installation tamination IMPORTANT Always refer to the PARTS MANUAL that corresponds to the specific model and serial number indicated on the serial tag plate of your vehicle This is essential to locating and ordering the correct components that were used during that particular manufacturing period It is also very helpful using the illustrations to clearly see and define the component being referred to If components are no longer listed in your Spare Parts Price List Distributors and Dealers Only generally the superceded section will indicate which part s will update or replace it All parts manuals are available in PDF format on CD Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 BR 35 SOWrklcm Brake System Argo Service Manual Removing a Brake Disc NOTE When servicing a left side brake disc you will need to remove the driven clutch from the transmission Refer to Removing the Driven Clutch in section CS of t
13. screws CONQUEST MODELS or retightening the gear clamp on the overhead mounting bracket BIGFOOT amp RESPONSE MODELS v Apply blue LOCTITE 242 to the threads of the brake disc mounting bolt and install it along with the lockwasher clamping washer and any other spacers or washers that were used previously See NOTES on page BR 37 On vehicles produced from S N CB16459 RB16446 BF11143 S11188 SN11196 1 Apply anti seize compound to the spline of the output shafts IMPORTANT A small number of vehicles used a shim washer in behind the brake disc This shim washer will need to be reinstalled to the output shaft before the brake disc is slipped on This is required to align the brake disc to the hydraulic caliper properly Take note of the transmission serial number to correctly identify these vehicles All 6 wheel hydraulic brake vehicles with serial numbers between BF11321 amp BF11390 All 8 wheel vehicles with serial numbers between RB16700 amp CB16778 Ontario Drive amp Gear Limited BR 39 www odg com PH 519 662 2840 FAX 519 662 2421 VA Brake System Argo Service Manual 11 Align the spline of the brake disc with those on the output shaft and slip the disc on and up to the shoulder of the output See NOTE previous page 11 Re position the cooling duct and and secure with the two 1 4 20x1 phillip head screws CONQUEST MODELS or retightening the gear clamp on the overhead mounting bracket BIGF
14. style hand pump this works well for sucking the fluid from the reservoirs If this is not an option disconnect the brake hose from the caliper and allow the reservoir to drain through the hose into a container Pumping the steering levers speed up the draining process 2 Disconnect the brake line at the master cylinders Photo BR 22 Ontario Drive amp Gear Limited BR 15 www odg com PH 519 662 2840 FAX 519 662 2421 j Brake System Argo Service Manual 3 There are 2 bolts that hold the master cylinders to their mounting bracket These are secured by 2 nylon locknuts Remove the 2 nylon locknuts and remove the master cyl inders from the vehicle to a clean work bench Photo BR 23 NOTE Be aware of the plunger pins and rubber boots attached to the master cylinders Remove these to a workbench to prevent them from dropping into the lower body of the vehicle A new rubber boot is supplied with the master cylinder O ring kit and must be replaced when rebuilding a master cylinder Disassembling the Master Cylinder 1 Perform the servicing procedure Mas ter Cylinder Removal 2 Pull the piston and compression spring from the master cylinder Photo BR 24 A CAUTION Do not use a gripping tool to pull out the piston as this will scratch or damage the surface Use fingers only to pull out the piston If this does not work reinstall gasket and cylinder cover and blow compressed air Low Pressure 20 psi or less
15. the Hydraulic Brake System ccsssssccccsssssssccccccssccees BR 20 Brake Fluid TS OCHO icsccesceexceaccvecexsccecenssensesecensoavsestacessavenatsnsesseseesayse BR 21 Changing the Brake FUG sssissscccsessiscscccssscetexceesesscssencieosascaeseusesssceesesass BR 22 Hydraulic Brake Plunger Pin Adjustment scccssssssssssccceeees BR 23 Hydraulic Brake Plunger Pin Adjustment Steering Bar Style Supplement FAG OS vcarsccncencsensececcgsacecseacsccaceseosexssdssanssusvarcsausanacaseneecarssaess BR 8A Holding Brake Adjustment Hydraulic Brake System c000 BR 25 Inspecting the Hydraulic Brake HoOe sscscccccsssssscccccssssccees BR 26 Replacing the Hydraulic Brake HoOe ssssscccsssssssccccccsssssees BR 26 Mechanical Brake Maintenance Schedule 6x6 Vanguard Models BR 26 Mechanical Brake Caliper Removal sssscccccssssssscccccsssssscccccesees BR 27 Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 BRI OWEN Brake System Argo Service Manual Brake System Table of Contents Mechanical Brake Pad Inspection Y Replacement sssssees BR 29 Replacing the Brake Pads Mechanical ssssccccssssssssscccsssssssees BR 29 Installing the Brake Pads Mechanical ssscccccsssssssscccccsssssscocees BR 30 Mechanical Brake Caliper Installation ccccccsssssssssssssssscssssescees BR 31 Adjusting the
16. the rear power pack mounting bolt Turn each of these clockwise to lower the rear of the power pack frame assembly Photo BR 64 BR 36 Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 4 Perform the servicing procedure Removing the Brake Caliper Hydraulic or Removing the Brake Caliper Mechanical NOTE There is no need to disconnect the hydraulic brake fluid lines from the caliper 5 Rotate the tires to locate the connecting link of the idler chain 6 Remove the connecting link clip and pull the connecting link from the chain 7 Perform the servicing procedure Removing the Idler Chain in section WA 8 Remove the bolt lock washer and flat washer securing the brake disc to the output shaft of the transmission NOTE 6x6 Vanguards produced prior to S N 7332 will have a spacer beneath the flat clamping washer This is slipped over the extended part of the output shaft that protrudes past the end of the brake disc sprocket The 40 2x15 Brake discs manufactured from S N S7332 have been unified in length with the 50 2x13 brake disc and no longer require this spacer These lengthened brake discs are fully exchangeable with the older style NOTE 6x6 vehicles manufactured between S N S7332 amp S7937 amp prior to SN7929 use a washer s in behind the flat clamping washer to Lengthen the output shaft and prevent the 108 18 clamping washer from collapsing Argos produced fr
17. through this screw with a slight spitting of fluid Re tighten the screw and once again pump the brake system slowly a few more times Apply pressure to the steering lever again and hold Open the bleed screw gradually until fluid slowly releases Repeat this procedure until the fluid coming from the bleed screw is a full stream with no vis ible signs of air in the system NOTE Catch any purged fluid at the caliper bleed screw with a rag or small container of some sort 4 Replenish the master cylinder to the top of the viewing window and secure the cover and rubber gasket 5 Clean any stray brake fluid that might have found its way on to the brake disc with brake cleaner Brake fluid on the brake disc can seriously affect braking capabilities of the ARGO vehicle 8 Pump the steering levers a few times to build up proper pressure and locate the pads in the caliper assembly Ontario Drive amp Gear Limited BR 20 www odg com PH 519 662 2840 FAX 519 662 2421 Brake Fluid Inspection A WARNING Do not allow brake fluid to contact your eyes clothes or painted surfaces Brake fluid is extremely corrosive and can cause severe personal injury Wear protective eye goggles gloves and clothing If brake fluid contacts your eyes consult a physician immediately A CAUTION Regular inspection of the brake fluid is very important Low fluid levels can cause a reduction or loss in braking ability high fluid level
18. 40 Fax 519 662 2421 9 Install the new brake pad to the dead side housing and secure with screw Apply some LOCTITE 242 Blue to the threads of the screw before installing 10 Locate the live side brake housing and slip the shim washer into the cavity first Figure 8 before installing the brake pad Figure amp Installing Shim 11 Install the second brake pad to the top of the previously installed shim Reassembling the Emergency Parking Brake Caliper to the Vehicle NOTE The following example illustrates the assembly of the Left hand side Emergency Parking Brake Caliper Figure 6 Pad Removed Mounting bolts for both calipers are always inserted facing to the left with the head of the mounting bolt on the right 8 Lay out both Dead Side and Live Side Brake housings with hand side of the caliper Refer to Figures A amp B for correct new brake pads Figure 7 orientation of mounting bolts as well as washer amp shim loca tions A Left Side be Shim wi SA Thin Washers 4 Live Side Figure 7 Lay Out Housings Figure A Left Side BR 14A Ontario Drive amp Gear Phone 519 662 2840 Fax 519 662 2421 Gao iri leswn Assembling the Left Hand Side Emergency Parking Brake Caliper 12 Install the live side housing to the inside of the brake disc Insert 2 two mounting bolts with spacers to the head of each bolt Place a thin washer to each bolt on the inside of the mounting
19. Argo Service Manual Brake System Brake System Table of Contents General Instructions s eesseesseecseecssecssecssecsseecseecssecssecssecsseesseesssessseo BR 3 4 Brake System Maintenance cccccsssssssssccssssssscccccsesovocccccsssscvcccsseseses BR 5 Brake Pad Inspection Hyd raullic ssccccccsssssssccccssssssccccccsssscccees BR 6 Removing the Brake Pads Hyd raullic sscccccccssssssscccsssssscccccsees BR 6 Installing Brake Pads Hyd raullic scccccccsssssssccccssssssccccccssscsccees BR 8 Hydraulic Brake Caliper Maintenance Schedulle 0sssssee BR 9 Hydraulic Brake Caliper Removall ccsssssscccsssssssccccccssssscoeees BR 10 Hydraulic Brake Caliper Disassembly cccccccssssssccccsssssssccceessees BR 11 Hydraulic Brake Caliper Reassembl ccssssscccsssssssscccccessssees BR 12 Hydraulic Brake Caliper Installation ccccccssssssssccccscccssssssees BR 14 Removing the Master CylindeD cccccccssssssscscssssssccccccsssssscccessscces BR 15 Disassembling the Master Cylindet cccsssscccccssssssccccssssscscccseees BR 16 Master Cylinder Servicing amp Inspection ccccccccssssssccccssssssscocees BR 17 Master Cylinder ReassembDly ccc cscsssssssssscosescessssoosssssssssccscssesosossesesess BR 18 Master Cylinder Installation sssccccccssssssscccsssssssccccccsssssccccssees BR 19 Bleeding
20. OOT amp RESPONSE MODELS iv Apply blue LOCTITE 242 to the threads of the brake disc mounting bolt and install it along with the lockwasher and clamping washer 2 Perform the servicing procedure Installing the Idler Chains in Section WA of this service guide 3 Perform the servicing procedure Adjusting the Idler Chains in Section WA of this service guide 4 Perform the servicing procedure Hydraulic Brake Caliper Installation or Me chanical Brake Caliper Installation in this section of the service guide 5 Perform the servicing procedure Mechanical Brake Caliper Adjustment on all Vanguard models 6 Apply the brake at the steering lever to each brake disc and torque each bolt to the specified torque 7 Perform the servicing procedure Reinstalling the Firewall in Section VB of this service guide Parking Brake Some vehicles may have an additional parking brake system installed The following illustrates and describes the assembly and components of the parking brake setup Parking Brake Assembly 1 Locate the caliper bracket and slip 2 of the longer mounting bolts through the bracket Install 2 long spacers to the bolts as illustrated in Photo BR 69 Be sure to orient the brake bracket as shown The top hole closest to the back edge of the bracket should be facing towards you 2 Assemble the bracket assembly to the right hand side of the power pack frame and secure with 2 nylon locknuts Photo BR 70 Ontario D
21. amp Gear Limited BR 10A www odg com PH 519 662 2840 FAX 519 662 2421 nna ones nn WA Argo Service Manual Brake Steering System 3 Perform the servicing procedure Hydraulic Plunger Pin Adjustment Avenger Model in this section of the service guide 2 Re hook the springs and test Adjust either upper lower or both springs as necessary until the desired outcome 1s achieved Ontario Drive amp Gear Limited BR 11A www odg com PH 519 662 2840 FAX 519 662 2421 TAVA Accessory Instructions 850 98 Parking Brake Service Assembly o Ref Qty Part Description l 850 98 Kit Service Parking Brake includes Ref 2 7 1 2 l Cam Tension Spring compression 3 l Left amp Right Brake Pads 4 l Cam Arm Spring tension 5 l Brake Pad Retaining Screw 6 l Castle Nut 7 l Cotter Pin A WARNING Detailed information on standard workshop and safety procedures and general instal lation practices is not included in these instructions which have been prepared to assist qualified and competent personnel ODG assumes no responsibility or liability for PERSONAL INJURY or VEHICLE DAMAGE which results from any procedure performed including those procedures outlined in these instructions Before per forming an installation operation an individual must have determined to his her satis faction that personal injury or vehicle damage will not result from the installation pro cedure working environment or tools selected
22. and O Ring moval Inspect Hoses and Brake Caliper Service and Connections Repair Inspecting the Hydraulic Brake line Hydraulic Caliper Installation BR 14 Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 BR 9 SOWrklcm Brake System Argo Service Manual Remove Hydraulic Brake Caliper 1 Perform the servicing procedure Removing the Firewall Quick Release in section VB 2 Raise the vehicle off the ground 3 Disconnect the brake line at the caliper Photo BR 6 Be aware of the brake fluid present in the system Use a rag or small container to collect any initial fluid that may drain from the master cylinder until you can raise and secure the brake line high enough to stop the flow of fluid 4 Line up the hole provided in the brake disc with the hex head mounting bolts that secure the hydraulic brake caliper to the transmission housing To do this you will need to rotate the tires by hand until they are lined up Remove the 2 fasteners and flat washers Slide the caliper from the disc Photo BR 7 A WARNING NEVER attempt to align these with the engine running and in gear NOTE The left hand caliper requires the removal of the drive belt and driven clutch to access the mounting bolts at the transmission Refer to Removing the Driven Clutch in Section CS of this service guide NOTE When removing the caliper from the transmission take note of any shims that may have been us
23. ants in the brake fluid can damage components or cause premature wear to them This will result in a loss of braking effectiveness 1 To drain and replenish the brake system you will need to remove the firewall of the vehicle Perform the servicing procedure Removing the Firewall for your particu lar model in Section VB of this service guide 2 Remove the engine hood to access the master cylinders Remove both covers using the appropriate screwdriver 3 Locate the bleed screw on the hydraulic brake caliper Slowly loosen the brake caliper bleed screw and gently pump the steering lever to purge the brake fluid from the system Catch the used brake fluid at the bleed screw with a container for dis posal later 4 Continue to pump the fluid from the system while monitoring the master cylinder Repeatedly replenish the master cylinder while pumping the old fluid from the sys tem 5 When the old fluid at the rear bleed screw appears to be replaced by fresh fluid perform the servicing procedure Bleeding the Hydraulic Brake System 6 Add brake fluid to the master cylinder as necessary to a level just above the view ing window and secure the cover Ontario Drive amp Gear Limited BR 22 www odg com PH 519 662 2840 FAX 519 662 2421 Hydraulic Brake Plunger Pin Adjustment IMPORTANT It is critical that the master cylinder pistons are adjusted properly when the steering levers are at the dash block position Overheat
24. being referred to If components are no longer listed in your Spare Parts Price List Distributors and Dealers Only generally the superceded section will indicate which part s updates or replaces it All parts manuals are available in PDF format on CD e Hydraulic System Conquest Response Bigfoot Vanguard2 amp 6x6 Conquest Mechanical System 6X6 Vangaurd Ontario Drive amp Gear Limited BR 3 PH 519 662 2840 FAX 519 662 2421 j Brake System Argo Service Manual General Instructions A WARNING Detailed information on standard workshop and safety procedures and general Servicing operations is not included in this manual which has been prepared to assist qualified service personnel ODG assumes no responsibility or liability for PERSONAL INJURY or VEHICLE DAMAGE which results from any servicing procedure performed including those instructions outlined in this manual Before performing a servicing operation an individual must have determined to his her satisfaction that a personal injury or vehicle damage will not result from the servicing procedure or tools selected A WARNING All brake work should be performed by a qualified mechanic Braking Steering ability and vehicle performance will be seriously impaired if the braking system is not properly adjusted or maintained Property damage and or injury or death may result to the operator A WARNING Hydraulic fluid can cause serious irritation to sk
25. bracket Figure 9 l ive Side Housi gr i Washer Afi i lt AY aN Figure 9 Remounting Dead and Live Side Housings 13 Install the shim plate over the 2 two mounting bolts Figure 10 14 Next install two thick washers to the mounting bolts along with the dead side housing which is placed to the outside of the brake disc Figure 11 ead Side Housing Figure 11 Dead Side Housing 15 Install 2 more spacers to the ends of the mounting bolts Figure 12 16 Secure with the nylon locknuts and torque caliper assem bly to 215in lbs 24Nm Figure 13 Figure 12 Spacers BR 15A Ontario Drive amp Gear Phone 519 662 2840 Fax 519 662 2421 Wo earn 19 Locate the brake lever assembly and reattach the exten sion spring to the hole provided If the spring was com pletely removed it should be attached first to the tab on the mounting bracket then to the cam lever Figure 16 Figure 13 Secure With Nylon Locknuts 17 Install the compression spring to the stud of the live side housing Figure 14 Figure 16 Spring Attached 18 Install the 2 dowel pins to the cavities of the live side 20 Install the lever to the stud of the live side housing housing rounded side facing out Figure 15 Figure 17 Figure 17 Cam Installed 21 Start the castle nut but do not tighten down yet EMERGENCY PARKING BRAKE ADJUSTMENT ALL MODELS A WARNING The use
26. brake cable am nut Ontario Drive amp Gear Limited BR 9A www odg com PH 519 662 2840 FAX 519 662 2421 j E Brake Steering System Argo Service Manual 8 Re check the brake plunger piston to ensure it is still flush to the casting and fine adjust if necessary Install the rubber boot Steering Bar Centering Adjustment Early Model Avengers With Handle Bar Centering Springs Only In some circumstances it may be necessary to adjust the way in which the steering handle bar returns parallel to the dash in the centred position 1 Ensure that the steering handle bar rests parallel to the dash in the non braking posi tion when released from a right or left turn position Photo BR 5 NOTE If the steering handle bar does not centre parallel to the dash when released it may be necessary to adjust this This may be achieved by manually bending the end of the return springs where they are inserted into the welded retaining bracket on the steering column frame assembly Depending on the direction of the bend it will either increase the tension or reduce it when the spring end is inserted back into the bracket Photo BR 6 amp 7 NOTE Before making the spring adjustment thread the plunger pins together to make sure that they are not coming into contact with the steering arms and will in no way affect the way in which the steering handle bar returns to the centred position Unhook Spring Ends From Bracket Ontario Drive
27. cavities on 2 of the calipers and install 4 steel balls Tap lightly with a steel hammer to seat them into the cavities Photo BR 80 Ontario Drive amp Gear Limited BR 42 www odg com PH 519 662 2840 FAX 519 662 2421 las NOTE Do not install the bearing balls to the single caliper with the notched area 13 Assemble the ball joint to the brake cam as shown in Photo BR 81 Secure it with a nylon locknut Orient the cam as illustrated in the photo 14 Install 2 long and 2 short bolts to the two calipers without the steel balls The one caliper is also the one that is notched Photo BR 82 15 Locate the notched caliper and slip the compression spring to the longer of the two bolts Assemble the caliper to the inside of the left side caliper bracket Place a second compression spring to the bolt Photo BR 83 16 Place the other half caliper with the steel balls to the previously installed inside caliper Photo BR 84 Ontario Drive amp Gear Limited BR 43 PH 519 662 2840 FAX 519 662 2421 p Brake System Argo Service Manual 17 Place the previously assembled ball joint and cam to the longer of the two bolts Slip the flat washer on to the bolt at the cam first then start the 2 way locknut to both the front and rear caliper mounting bolts Photo BR 85 18 Repeat this procedure for the right hand side caliper assembly The inner caliper on the right hand side assembly is not notched 19 Th
28. ckness of the brake disc when the caliper is slipped back into position and remounted to the transmission 2 Remount the caliper to the transmission by aligning the access hole in the brake disc with that of the threaded mounting boss on the transmission Photo BR 5 LOCTITE the threads of the 2 hex head mounting bolts with blue LOCTITE 242 and secure the caliper with the 2 flat washers in place to the transmission Do not forget to install any shims that may have initially been between the caliper and trans mission mounting bosses Torque to specifications Ontario Drive amp Gear Limited BR 8 www odg com PH 519 662 2840 FAX 519 662 2421 Hydraulic Brake Calipers Maintenance Schedule Inspect every 50 hrs of vehicle operation A CAUTION The brakes must be inspected regularly by a qualified mechanic Damaged or leaking calipers can seriously impair the ARGO steering braking capability Severe personal injury or property damage could result from a damaged or poorly adjusted brake system Inspect the calipers for the conditions listed in the chart below and then perform the recommended servicing procedures Corrective Action Servicing Procedure Cracked or Broken Replace Immediately Hydraulic Brake Caliper Re Calipers moval Broken or Missing Brake Caliper Service CotterPins and Repair Hydraulic Caliper Installation BR 14 Hydraulic Fluid Inspect Caliper Hydraulic Brake Caliper Re Leakage Casting
29. crew back into the threaded mount of the caliper casting Photo BR 18 Cap with the rubber plug 10 Slide the brake pads into the calipers and secure with 2 new cotter pins Hydraulic Brake Caliper Installation 1 Remount the caliper to the transmission by aligning the access hole in the brake disc with that of the threaded mounting boss on the transmission LOCTITE the threads of the 2 hex head mounting bolts with blue LOCTITE 242 and secure the caliper with the 2 flat washers to the transmission Photo BR 19 Torque to specifications See bottom NOTE on age BR 10 Ontario Drive amp Gear Limited BR 14 www odg com PH 519 662 2840 FAX 519 662 2421 las 2 Reattach the brake line at the caliper Photo BR 20 NOTE Always use new copper washer seals at all brake line connections 3 Perform the servicing procedure Bleed ing the Hydraulic Brake System Removing the Master Cylinder A CAUTION Clean the master cylinder casting and caliper casting and fittings This will prevent dirt from contaminating the brake system Contaminants in the brake fluid can damage components or cause premature wear This will result in a loss of braking steering effectiveness NOTE To rebuild a master cylinder removal of the component is necessary to insure a clean and thorough job 1 Remove the covers from the master cylinders and empty the cylinders of their con tent Photo BR 21 If you have access to a vacuum
30. d Y the fluid inlet hole is stripped 3 Lubricate all component parts with clean fresh Dot 5 Silicon Brake Fluid 4 Before assembly a new rubber boot and new primary and secondary seals are re quired These are available in the replacement assembly Master Cylinder O Ring Kit Master Cylinder Reassembly 1 Slide the new primary and secondary seals on to the piston Orient as in Photo BR 25 A CAUTION Do not damage the seals during the installation 2 Install the compression spring on to the piston Make sure the small end of the spring is mated to the piston Photo BR 26 NOTE Models manufactured prior to May 25 2000 have a shorter non tapered spring which need only be inserted into the master cylinder followed by the piston The older and newer style spring are fully exchangeable if necessary but should be changed as a set Vehicles manufactured from S N CB17145 RB17120 BF 11608 SNII630 will have the newer spring style Ontario Drive amp Gear Limited BR 18 www odg com PH 519 662 2840 FAX 519 662 2421 aie kLesm 3 Install the piston into the piston bore Slide the end with the primary seal in first Photo BR 27 4 Temporarily install the cover and gas ket onto the master cylinder reservoir Master Cylinder Installation 1 Line up the holes in the mounting bracket with those of the master cylin der and insert the 2 mounting bolts Photo BR 28 NOTE Conquest models require the rear m
31. d a possible brake lockup The piston being adjusted too far out on the other hand could affect the braking ability of the vehicle for both turning and stopping efficiently If this is a steering assembly with NEW spring pins installed apply firm pressure to handle bars in each steering direction to seat the roll pins before proceeding with the following adjustments Also ensure the brake system has been bled properly and purged of any air in the system 1 Loosen the set screw securing the collar to the plunger pin Photo BR 1 This will free the collar to slide along the pin 6 ang Adjust s i Loosen EN n t re gl a 3 Locate the cable length adjustment for the hand brake lever near the steering arm and thread in to slacken the brake cable across the steering arms Photo BR 2 Please note this step is only required on earlier models manufactured up to serial number V22440 Photo BR 2 Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 BR 8A po Argo Service Manual Brake Steering System IMPORTANT Both left and right steering arms should be pulled back to their rear most limit before the plunger pin adjustment is made On earlier models you should use both hands to pull back on each arm to ensure they are back in the rear most position Photo BR 3 Later models utilize a double spring behind the plunger in the master cylinder which will provide plenty of spring tension to push th
32. drill bit 4 Remove the pad and discard Photo BR 43 Installing the Brake Pads Mechanical 1 Place the new brake pad on to the caliper Be sure that the counter sunk side is facing up Photo BR 44 2 Using a pop riveting tool fasten the brake pad to the caliper Photo BR 45 NOTE The tip of the riveting tool may need to be modified to allow it to fit into the counter bored hole in the pad This will ensure that the head of the rivet is tight against the pad when it is pulled IMPORTANT Make sure that the brake pad is completely flat to the caliper when pulling the rivets and that there is no obstruction between the caliper and the back side of the pad Ontario Drive amp Gear Limited BR 30 www odg com PH 519 662 2840 FAX 519 662 2421 Bey Mechanical Brake Caliper Installation 1 Lay out mechanical brake caliper components onto the work bench Photo BR 46 Take note of the orientation of the brake cam to the adjustment rod and be sure to assemble accordingly if this assembly has been disassembled for any reason 2 Take the longer of the two mounting bolts and place it through the front hole of the caliper Photo BR 47 3 Insert the shorter of the two bolts into the rear hole of the caliper Photo BR 48 4 Place 1 compression spring on to the longer of the two mounting bolts Photo BR 49 On the right hand side brake assembly make sure to assemble the parking brake bracket first before i
33. e Steering System Read all the instructions thoroughly before starting and attempting ANY repairs Consult your Argo Dealer if you have any questions Disassembling the Moto Cross Style Steering Column All Models 1 Perform the servicing procedure Removing the Firewall 2 Cut the tie wrap securing cables to the steering column 3 Remove the 4 fasteners securing the steering bar to the steering column assembly Photo ST 1 4 Remove the Nylon Locknut and Flat Washer from the top of the Lower Handle Bar Clamp Discard the nylon locknut Photo ST 2 5 Remove the Lower Handle Bar Clamp from the steering shaft Photo ST 3 IMPORTANT Be aware of the small key s installed into the steering shaft and ensure they are installed when reassembling the steering system 6 Disconnect the hand brake lever cable at the steering arms 7 Apply pressure to the left hand side plunger pin by pushing on the steering arm with the palm of your hand and insert a shim between the locking collar and the welded tab stop Photo ST 4 Repeat on the right hand side master cylinder Follow ing this procedure will ensure that there is no interference between the plunger pins and steering arms when sliding the shaft from the steering column Ontario Drive amp Gear Limited BRIA www odg com PH 519 662 2840 FAX 519 662 2421 j E Brake Steering System Argo Service Manual Avenger Models Only i Slip the Steering Shaft from the
34. e holding brake system is correctly adjusted Photo BR 35 5 If not turn the holding brake adjuster screw in the direction required for correct distance A CAUTION If the holding brake system is too tight excessive pressure in the brake system will damage the seals Ontario Drive amp Gear Limited BR 25 www odg com PH 519 662 2840 FAX 519 662 2421 j A XOWONdICOM Brake System Argo Service Manual Hydraulic Brake Hoses Maintenance Schedule Inspect every 25 hrs of vehicle operation 1 Inspect the condition of the hydraulic hoses Replace them if o the hoses are cracked or punctured o brake fluid leakage 1s noted on the hose nearby assemblies or around hose fittings 2 Perform the servicing procedure Replacing the Hydraulic Brake Hoses below Replacing the Hydraulic Brake Hoses A CAUTION Clean the master cylinder casing and the caliper casting and fittings This will prevent dirt from contaminating the brake system Contaminants in the brake fluid can damage components or cause a loss in braking or steering effectiveness 1 Remove cover and gasket seal from the master cylinder reservoir 2 Disconnect the hose from the caliper Place a catch tray under the free end of the hydraulic hose and allow the hose and master cylinder reservoir to drain 3 Disconnect the hydraulic hose from the master cylinder 4 Replace the hose 5 Reconnect the hydraulic hose to the master cylinder Make sure both c
35. e steering arms back fully Setting Plunger Pin Adjustment 1 Sitting in the vehicle driver s seat en Sure sure that the steering handle bar is parallel with the dash Plunger pins should be threaded so they are in con tact at the back with the steering arms Place the collar tightly up against the welded tab stop and secure the set y screws with blue LOCTITE IN Pi hger Flush With Casting 2 Thread the plunger pins until the master cylinder plunger piston is flush with the casting of the master cylinder Photo BR 4 Re tighten all plunger pin jam nuts Recheck that steering handle bar is parallel with dash and repeat procedure if neces sary IMPORTANT If you have been servicing the brake system add fresh clean DOT 5 brake fluid and rebleed the brakes purging all air from the brake system Reinstall the master cylinder covers When complete apply steering input to both sides to pump up the brakes Recheck plunger setting and adjust as necessary IMPORTANT Ensure the tab stops that the collars come into contact with are not bent in any way This will affect how the plunger pin sits when the opposite brake is applied Any deformity in the tab could cause the plunger pin to become misaligned with it s own steering arm during the application of the opposite brake 7 Re adjust the hand brake lever cable until any slack has been removed between the two steering arms and is on the verge of engaging the brakes Tighten the
36. ed between the caliper and transmission mounting boss Earlier models may have employed shims to correctly align the calipers with the brake discs Ensure that these are reinstalled when remounting the caliper Ontario Drive amp Gear Limited BR 10 www odg com PH 519 662 2840 FAX 519 662 2421 5 Remove the caliper to a clean work area Hydraulic Brake Caliper Disassembly 1 Perform the servicing procedure Remove Hydraulic Brake Caliper 2 Work on a CLEAN dry surface Locate and remove the 2 cotter pins securing the pads in the caliper and remove the brake pads 3 Remove the piston from each half by applying compressed air Max 20 psi or less to the hydraulic hose inlet Place a rag in between the caliper to absorb the shock of the piston when it pops from the caliper Photo BR 8 4 Place the caliper into an aluminum jawed vise with the 4 hex head fasteners facing B A CAUTION Always wear eye protection when using compressed air Caliper parts could fly apart causing serious injury NOTE Depending on the manufacturing date of the vehicle being serviced the caliper halves may be secured together by either 2 or 4 mounting bolts Vehicles manufactured prior to S N CB 12455 RB 12474 amp SN 8285 utilize the 2 bolt configuration The 4 bolt style is fully exchangeable and replaces the 2 bolt pattern 5 Remove the socket head bolts that secure the caliper halves together Photo BR 9 6 Take the caliper assembly
37. g to remove the entire caliper from the mounting bosses on the transmission housing or cover Vehicles equipped with Knott brake calipers also allow for brake pad removal by removing the 2 cotter pins securing the pads and pulling them straight up and out of the caliper Vehicles produced from CB12454 RB12473 amp SN 3284 Grimeca brake calipers only utilize an additional two MS bolts per caliper This new setup restricts the pads from being slipped out towards the drivers compartment The caliper must be removed to slip the pads out through the front of the caliper The following procedure applies to these later models 1 Perform the servicing procedure Re moving the Firewall in section VB of this service guide 2 Raise the vehicle off the ground 3 Line up the hole provided in the brake disc with the 2 hex mounting bolts that Ontario Drive amp Gear Limited BR 6 www odg com PH 519 662 2840 FAX 519 662 2421 secure the hydraulic brake caliper to the transmission housing To do this you will need to rotate the tires by hand until they are lined up Photo BR 1 A WARNING NEVER attempt to align these with the engine running and in gear NOTE You may leave the brake fluid line connected to the caliper 4 Remove the 2 fasteners and flat wash ers Slide the caliper from the brake disc Photo BR 2 NOTE The left hand caliper requires the removal of the drive belt and driven clutch to access the
38. ger pin Photo BR 32 5 With the jam nut loosened the plunger pin may be threaded either in or out In any case the end result should have the master cylinder piston flush with the casting of master cylinder housing Photo BR 33 Check this adjustment by using your finger feeling the edge of the master cylinder casting and the top of the piston 6 Secure the jam nut 7 Remove your spacer at the steering assembly dash block 8 Sit in the vehicle and pull back on both levers checking to make sure the levers have the 1 4 clearance before engagement and come back evenly Ontario Drive amp Gear Limited BR 24 www odg com PH 519 662 2840 FAX 519 662 2421 xoWoHdd com Holding Brake Adjustment The holding brake system has been factory adjusted to ensure proper braking effectiveness However before the vehicle is used for the first time and after every 25 hours of operation the adjustment of the holding brake must be inspected A WARNING The use of an improperly adjusted holding brake is a serious hazard and could lead to vehicle damage or personal injury 1 Pull each steering lever back until you feel resistance 2 While holding the levers back push each holding brake handle down until it rests against the brake lever stop Photo BR 34 3 Check the distance between the holding brake stop on each steering lever and the holding brake adjusting screw 4 Ifthe distance is approximately 1 16 1 6mm th
39. his service guide l Ze Perform the servicing procedure Removing the Firewall in section VB Loosen off the power pack frame On 6x6 vehicles manufactured prior to S8131 locate and loosen off the four 1 2 20x1 5 power pack frame mounting bolts Refer to Section 4 0 Power Pack As sembly in the appropriate parts manual There are two located in front of the idler axles and two visibly located behind the idler axles These bolts are threaded into nuts welded to the lower frame assem bly On ARGOS manufactured from SN7841 S8131 and all RB CB BF amp C vehicles loosen the locknut in front and behind the idler axles These are threaded to 2 mounting bolts in serted through the power pack frame from right to left and attached at the lower frame Photo BR 63 Y A Xx e 2 Second Nut In Front of Idler Axle J PS BR 63 On 6x6 models produced from 7304 and prior to 8131 undo the jam nuts at the chain tensioner bolts and using an allen head wrench turn the adjustment bolts counter clockwise to lower the back end of the power pack frame This will slacken the idler chains and allow for removal Models prior to this serial number will require a 3 4 socket on the adjustment bolt head to lower the power pack frame Next loosen off the idler chains On ARGOS manufactured from SN7841 S8131 and all RB CB BF amp C vehicles locate the two 3 8 16x3 bolts threaded into the lower frame channel beneath
40. ich are subject to more severe use wet or dusty conditions will require more frequent servicing NOTE Please refer to the appropriate illustrated parts manual for the vehicle being serviced The parts manual is identified with either the vehicle s model number serial number or both written on the front cover These parts manuals are availible on CD in PDF format Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 BR 5 SOWrklcm Brake System Argo Service Manual Brake Pad Inspection Replace the brake pads if Pad thickness is less than 0 10 Hydraulic Brake Pads 9 Pad thickness 1s worn to 1 8 3mm Mechanical Brake Pad Y The pads are glazed over and brake performance is affected Y The pads are coated with oil or grease Removing Brake Pads Hydraulic NOTE The hydraulic brake system is used on all models of ARGO vehicles with the exception of the Vanguard 6x6 To replace hydraulic brake pads Gremica Calipers only on models manufactured prior to 1996 remove the cotter pins securing the pads within the caliper and slip the brake pads from the caliper towards the drivers compartment This procedure for replacing pads may be used proir to serial numbers CB12454 RB12473 amp SN 3284 Gremica brake caliper halves used in production during this earlier manufacturing period were secured together by two M10 bolts only allowing the pads to be pulled from the calipers without havin
41. in and eyes In case of contact flush thoroughly with water and contact a doctor if eyes have been exposed A CAUTION Use only Dot 5 Silicon Brake Fluid in the hydraulic brake system Use of other brake fluids may damage components and could void warranty on the brake system Never allow dirt water used brake fluid or any other contaminants to enter the hydraulic brake system Also never combine different types of brake fluids keeping in mind they may be incompatible with each other Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 BR 4 Sweat Lem Brake System Maintenance A CAUTION Regular maintenance of the brake system is essential to both good vehicle performance and personal safety Poorly maintained brakes can result in a decrease in braking steering efficiency vehicle performance or damaged brake discs Maintenance schedule 1 Every 100 hours of vehicle operation perform the servicing procedure Brake Pad Inspection Mechanical 2 Every 25 hours of vehicle operation Perform the servicing procedure Brake Pad Inspection hydraulic 3 Every 30 hours of vehicle operation perform the servicing procedure Adjusting The Mechanical Brake Caliper Vanguard Models only 4 Every 50 hours of vehicle operation Perform the servicing procedure Inspect Brake Fluid Level Condition NOTE The intervals shown in this schedule are based on average operating conditions Vehicles wh
42. ing of the brake system could occur due to the piston being adjusted too far in This could cause a drag on the system and a possible brake lockup On the other hand the piston being adjusted too far out could affect the braking ability of the vehicle by causing it to be less aggressive giving it poor turning capabilities This adjustment will also set both handle bars at an even distance from the dash block when both are applied NOTE A 1 4 clearance should be set between the steering levers and the dash block before engagement of the plunger pins This will provide some leeway if the handle bars are pulled back slightly while driving without the intention of applying them riding the brakes 1 Remove the firewall 2 Loosen the 1 or 2 set screws securing the collar to the plunger pin Photo BR 29 This will free the collar to slide along the pin 3 A spacer measuring approximately 1 4 must be temporarily placed between the steering levers and the dash block Photo BR 30 Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 BR 23 ales Brake System Argo Service Manual 3 Push the collar up tightly against the tab stop of the steering bracket assembly and re tighten set screw s Apply Blue 242 LOCTITE to the threads of the set screw The 1 4 clearance between the dash block and engagement of the plunger pin is now set Photo BR 31 4 Locate and loosen the jam nut on the adjustable plun
43. ld be installed such that the slot of the pin is parallel to the shaft and an equal amount of pin protrudes on each side of the shaft Photo ST 9 ii Slip the first Steering Arm on to the Steering Shaft followed by the Retaining ring seating it to the groove on the shaft Install the second Steering arm Orient them as illustrated in Photo ST 10 111 Install the 2nd Spring Pin followed by a centering spring Install the 3rd Spring Pin followed by a 2nd centering spring and 4th Spring Pin Photo ST 11 amp 12 NOTE Please observe the orientation of the free end of the springs Each is pointing in the same direction as the steering arms Photo ST 13 Ontario Drive amp Gear Limited BR 3A www odg com PH 519 662 2840 FAX 519 662 2421 i Brake Steering System Argo Service Manual i Pi J D e r F a 8 f SANA lt eyway Facing UPA a E i p Y 2 a i Poe E Ma 2 j AS Fa ta A a r tal d n a se ay e oe AA A F al j F aig if 1 Install the Spring Pin at the 2nd hole from the end on the Steering Shaft The roll pin should be installed such that the slot of the pin is parallel to the shaft and an equal amount of pin protrudes on each side of the shaft Photo ST 14 11 Slip a steering arm on to the shaft and up against the previously installed Spring Pin 111 Next Install a Retaining Ring to the machined groove on the Steering Shaft This retaining ring
44. mounting bolts to the transmission Refer to Removing the Driven Clutch in Section CS of this service guide NOTE When removing the caliper from the transmission take note of any shims that may have been used between the caliper and transmission mounting boss Earlier models may have employed shims to correctly align the calipers with the brake discs Ensure that these are reinstalled when remounting the caliper 5 Remove the 2 cotter pins securing the brake pads within the caliper and slide the brake pads out through the front Photo BR 3 6 Perform the procedure Hydraulic Brake Pad Inspection Ontario Drive amp Gear Limited PH 519 662 2840 FAX 519 662 2421 BR Brake System Argo Service Manual Installing Brake Pads Hydraulic A CAUTION When replacing worn or contaminated pads replace both pads in the brake caliper assembly even if both pads do not require replacing Using one new and one old brake pad in a caliper assembly may provide poor braking steering performance NOTE When replacing brake pads always use new cotter pins 1 Slip the new pads into the caliper Install and bend the cotter pins to secure the new pads in place Photo BR 4 NOTE Before installing the pads into the caliper make sure that the brake caliper pistons are pushed back into the caliper housing as far as possible This will enure that the new pads can be spread far enough apart from each other to accommodate the thi
45. moval in Section ES of this service guide e Install a wheel puller on the brake disc and remove it from the transmission output shaft NOTE Vehicles manufactured prior to October 21 1999 utilize keyways machined within the brake disc There are two 1 4 x 1 4 keys used on the keyed output shafts Vehicles produced from S N s SILI188 SN11196 CB16459 RB16446 BFIII43 are splined These accommodate the newer Style splined output shafts These splined brake discs are fully exchangeable with the keyed versions if desired however this would also mean replacing the output shaft as well Keyed brake discs and outputs are still available Ontario Drive amp Gear Limited BR 38 www odg com PH 519 662 2840 FAX 519 662 2421 Installing the Brake Disc On vehicles produced prior to S N CB16459 RB16446 BF11143 S11188 amp SN11196 1 Apply an anti seize compound to both output shafts 1i Place both keys in the keyways of the output shafts 111 Align the keys with the keyways on the brake disc and slide the disc on to the shaft The sprocket on the brake disc should be facing outward Photo BR 68 N OT E Vehicles equipped with the brake cooling system will require the cooling duct to be moved out of the way far enough to allow the brake disc on Seat the brake disc firmly against the shoulder of the output shaft iv Re position the cooling duct and and secure with the two 1 4 20x1 phillip head
46. ng the removal of the firewall To adjust the steering levers tighten both oe brake adjustment nuts refer to DIAGRAM Brake Pads BR 62 clockwise using a 1 2 deep socket E AA and ratchet until the levers are both 18 cm 7 da from the dash DO NOT OVER TIGHTEN Holding Brake Adjustment Although the holding brake system has been AA Right Brake factory adjusted 1t should be checked after A SAAN Caliper Assembly Brake Rod ais every 25 operating hours to ensure the correct ciamps V adjustment Phillidas Nut Adjustment Lock Nut Phillidas Lock Nut A WARN L N G BR 62 Brake Adjusting Rod The use of an improperly adjusted holding brake is a serious safety hazard and could lead to vehicle damage or personal injury 1 Pull the left steering lever back 2 While holding the lever lift the spring loaded brake lever until 1t contacts the pin in the steering lever Ontario Drive amp Gear Limited BR 34 www odg com PH 519 662 2840 FAX 519 662 2421 xoWoHdd com 3 Release the steering lever allowing the holding brake lever to lock the left brake on 4 Ifthe steering lever grip is approximately 18 cm 7 from the dash the holding brake system 1s correctly adjusted 5 If the distance from the dash is greater refer to Steering Lever Adjustment to properly set the left lever Brake Disc Inspection Maintenance Schedule Inspect every 50 hrs of vehicle operation IMPORTANT Badly worn brake
47. nstalling it to the power pack bracket Photo BR 50 6 Install the left caliper half to the brake bracket on the power pack frame Photo BR 51 7 Place the second compression spring to the caliper Photo BR 52 Ontario Drive amp Gear Limited BR 31 www odg com PH 519 662 2840 FAX 519 662 2421 6 Wondalcom Brake System Argo Service Manual 7 Apply a little axle grease to the two ball bearing cavities of the second caliper and place two ball bearings into these cavities Lightly tap each ball bearing with a soft faced mallet to seat it within the cavity Photo BR 53 NOTE The caliper with the 2 steel ball bearings are always on the side of the brake cam 8 Place the second caliper to the mount ing bolts 9 Install the cam assembly and flat washer to the longer of the two mounting bolts Photo BR 54 amp 55 10 Install a flat washer and locking nut to the mounting bolt at the cam and a lock ing nut at the rear mounting bolt Photo Ontario Drive amp Gear Limited BR 32 www odg com PH 519 662 2840 FAX 519 662 2421 SW Lem NOTE Always use new locknuts whenever servicing mechanical brake calipers Adjusting the Mechanical Brake Caliper Vanguard Models 1 Remove the vehicle firewall and proceed to tighten both front and rear nuts so that the mechanical caliper assembly is snug to the brake disc Photo BR 57 This is a good starting point to begin brake caliper clearance adjustment
48. om S7937 amp SN7929 no longer require these washers because the output shaft dimension has been lengthened If an earlier vehicle which utilized these washers has had the transmission output shafts replaced with new ones these washers will no longer be required during reassembly NOTE If the ARGO is equipped with a brake cooling fan system as is the case with all CB RB BF amp C vehicles you will need to loosen and slide the brake shroud out of the way before the brake disc can be slid off the output shaft 9 On Conquest models loosen the two 1 4 20x1 pan head screws securing the brake cooling duct to the power pack frame Photo BR 65 Slide the ducting clear of the brake disc On Bigfoot amp Response Models loosen off the gear clamp that secures the brake cooling duct to the overhead bracket of the brake discs Photo BR 66 Ontario Drive amp Gear Limited BR 37 www odg com PH 519 662 2840 FAX 519 662 2421 j 6x6 Wonldicom Brake System Argo Service Manual Gap Required To Slip Disc Off k i ik UDR Y BR 66 10 Slide the brake disc from the output shaft NOTE To remove the brake disc you may need to raise the power pack up by prying at the rear of the power pack frame Raise it high enough for the brake disc to clear the drive sprocket when slipping it from the output shaft Photo BR 67 NOTE If the brake disc won t move e If removing the right hand brake disc perform the servicing procedure Battery Re
49. opper washer seals have been replaced with new ones at the banjo bolts 6 Perform the servicing procedure Bleeding the Hydraulic Brake System Mechanical Brakes Vanguard Models Maintenance Schedule Inspect every 25 hrs of vehicle operation A CAUTION The brakes must be inspected regularly by a qualified mechanic Damaged calipers or badly worn brake pads can seriously scratch the face of the brake discs and cause a reduction in steering and braking ability of the ARGO vehicle Severe personal injury could result from a damaged or poorly adjusted brake system Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 BR 26 Sweat Lem The mechanical brake caliper assembly probably needs adjustment and servicing when o a drag on vehicle power and acceleration occurs o a loss of braking effectiveness is noted o steering does not respond properly o excessive strength 1s required to steer or stop the vehicle Component Condition of Component Action Required Caliper Bent Cracked or Broken Replace Mounting Bolts Worn Shaft or Stripped Shaft Replace Compression Springs Twisted or Broken Replace Ball Bearings Worn or Missing Replace Brake Pads See Mechanical Brake Pad Inspection amp Replacement For a thorough examination of the brake pads perform the servicing procedure Mechanical Brake Pad Inspection amp Replacement Mechanical Brake Caliper Removal 1 Remove the locknut
50. ounting bolt to also secure the igniter box at the master cylinder 2 Reinstall the nylon locknuts and tighten to anchor the master cylinders into position 3 Reconnect the brake lines to the master cylinders Always use new copper washer seals on the banjo bolts Torque to specifications 4 Refill the master cylinders using DOT 5 brake fluid Use of other types of brake fluids or combining different types of brake fluids may result in damage to steering braking components or seriously impair the way in which the vehicle performs Ontario Drive amp Gear Limited BR 19 www odg com PH 519 662 2840 FAX 519 662 2421 j Brake System Argo Service Manual 5 Perform the servicing procedure Bleeding the Hydraulic Brake System below Bleeding the Hydraulic Brake System 1 Remove the rubber plug from the bleed screw at the brake caliper 2 With the bleed screw still tight purge any air from the system by pumping the steer ing handles slowly When there are no longer visible signs of air bubbles observed in the master cylinder replenish it with more fluid to bring it back up to the top of the window 3 Next apply steady pressure to the steering lever until the brake is fully engaged Hold the steering lever in this position and slowly loosen the caliper bleeding screw 1 4 turn Open the bleed screw only enough to slowly release fluid out of the screw If there is any air still present in the system it will be noticeable
51. read the emergency parking brake rods into each of the ball joints at the cam until there is approximately 12 inch of thread exposed Attach the other end of the rod to the shaft assemblies and secure with a cotter pin Photo BR 86 20 Tighten down both locknuts of the me chanical caliper system until the brake pads are snug to the brake discs Photo BR 87 Adjusting the Caliper 21 Loosen the locknut of the rear caliper bolt until it turns freely by hand 22 Loosen the locknut of the caliper at the cam until the caliper is released from the brake disc There should now be movement in the caliper Recheck the rear adjust ment bolt to see if it still turns by hand If not adjust as necessary until it does Ontario Drive amp Gear Limited BR 44 www odg com PH 519 662 2840 FAX 519 662 2421 Biya 23 Tighten the jam nut at the ball joint on the parking emergency brake rod Photo BR 88 24 Apply blue 242 LOCTITE to the threads of the bolt at the brake cam and thread a second locknut up to and against the first one Hold the inner nut with an open end wrench while tightening the second one up against it Photo BR 89 amp 90 25 Locate the brake cooling duct and insert a spacer into the 2 mounting holes on each side of the duct Photo BR 91 26 Mount the brake cooling duct to the top of the transmission using a bolt flat washer and nylon locknut Fasten this to the hole in the driven clutch guard Pho
52. rive amp Gear Limited BR 40 www odg com PH 519 662 2840 FAX 519 662 2421 Argo Service Manual Brake System 3 Assemble the second caliper bracket to the left side of the power pack frame using 2 of the shorter mounting bolts and 2 short spacers The bracket should be oriented as the right side with the top hole closest to the back edge of the bracket facing the assembler Secure with 2 more locknuts Photo s 71 amp 72 4 Brackets should look as in BR 73 from the assembler s perspective 5 Lay out all mechanical brake components for assembly Photo BR 74 Ontario Drive amp Gear Limited BR 41 www odg com PH 519 662 2840 FAX 519 662 2421 j Brake System Argo Service Manual 7 Locate the parking brake lever assembly and insert it at the back of and in between the power pack frame channel Slip the left parking brake shaft assembly through the parking brake lever Photo BR 75 8 Locate and install the right hand side parking brake shaft through the parking brake lever from the opposite side as in Photo BR 76 Try E FE _ i M BF ld A mes 9 Install 4 roll pins to secure both shafts to the parking brake lever Photo s BR 77 amp 78 y yo m a 11 Thread the jam nut to the 2 parking emergency brake rods Photo BR 79 12 Lay out the 4 mechanical brake calipers 1 is notched on one side on to a clean work area Apply a small quantity of axle grease to each of the ball bearing
53. s or brake fluid contaminated with oil dirt or water can damage the seals or other component parts of the hydraulic brake system Use only Dot 5 silicon brake fluid Other brake fluids may not be compatible with ARGO brake components and operating temperatures Inspecting the Brake Fluid Condition Maintenance Schedule Inspect every 50 hours of vehicle operation 1 Locate the master cylinder in the engine compartment It is located at the top of the transmission NOTE To access the master cylinder cover remove the hood assembly You can then remove the cover screws with a screwdriver 2 Clean the casing and lid of the master cylinder This will prevent dirt or other con taminants from entering the reservoir 3 Using a screwdriver unfasten the cover screws and remove the cylinder cover and gasket Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 BR 21 SW Brake System Argo Service Manual Inspect the condition of the brake fluid and replace if Y the fluid appears cloudy the fluid appears discoloured 4 the fluid contains particles of dirt rust water or other contaminants the level is below the viewing window If any of these conditions are noted Perform the servicing procedure Changing the Brake Fluid below Changing the Brake Fluid A CAUTION Clean the master cylinder casing and fittings This will prevent dirt from contaminating the brake system Contamin
54. sher and anew 117 29 Nylon Locknut to the threaded end of the steering shaft Photo ST 22 13 Tighten down the Nylon Locknut snug Back off the Locknut just enough to al low the Flat Washer below to be turned by hand Do not overtighten Ensure the shaft turns freely with minimal end play Photo ST 23 Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 BR 6A Argo Service Manual Brake Steering System 14 Set the Handle Bar assembly into place and cover with the Upper Handle Bar Clamp The Handle Bar clamp is se cured into place with four fasteners Tighten down the fasteners in an X pattern indifferent to starting location at a torque specification of 10 12 Ft LBS 13 5 16N m Photo ST 24 15 Apply firm pressure to handle bars in each steering direction to seat the roll pins 16 Reattach the hand brake lever Cable across the two brake Steering Arms 17 Perform the servicing procedure Hydraulic Plunger Pin Adjustment Ontario Drive amp Gear Limited BR 7A www odg com PH 519 662 2840 FAX 519 662 2421 j ne Brake Steering System Argo Service Manual Hydraulic Brake Plunger Pin Adjustment IMPORTANT It is critical that the master cylinder pistons are adjusted properly when the steering handle bar is at the centered position Overheating of the brake system could occur due to the piston being adjusted too far in This could cause a drag on the system an
55. t the way in which the calipers return to the normal position when they are released by the driver Usually they will not return and tend to stick in the brake on position Mechanical Brake Pad Inspection amp Replacement Inspect the condition of the brake pads Replace the pads when they are worn to 1 8 or less in thickness the pads are worn unevenly a sign that could relate to a warped or bent caliper the pads are glazed over and poor braking steering performance has been noted the brake pads are contaminated with oil or grease A CAUTION When replacing worn or contaminated brake pads replace both pads in the brake caliper assembly even if both pads do not require replacing Using one new and one old brake pad in a caliper assembly may provide poor braking and steering performance Quality ARGO replacement brake pads are available only in a set of 2 1 Perform the servicing procedure Me chanical Brake Caliper Removal Replacing the Brake Pads Mechanical 2 Using a high speed drill remove the heads of the rivets with a 3 16 drill bit Photo BR 42 See caution on follow ing page Ontario Drive amp Gear Limited BR 29 PH 519 662 2840 FAX 519 662 2421 j Brake System Argo Service Manual A CAUTION Take care in drilling out old pop rivets Damage to the caliper casting could occur requiring a more expensive caliper replacement 3 Clear the remainder of the rivets with a 11 64
56. to BR 92 amp 93 Ontario Drive amp Gear Limited BR 45 www odg com PH 519 662 2840 FAX 519 662 2421 j Brake System Argo Service Manual 27 Mount the other side of the brake cooling duct using a bolt lock washer and flat washer Attach this end using the same bolt that secures the steering bracket to the rear threaded transmission boss Photo BR 94 IMPORTANT Before securing the brake cooling duct be sure that the engine wire harness plug is accessible above the ducting Conquest Models Only Photo BR 95 Brake Cooling System All 6x6 Bigfoot and Eight wheel vehicles with hydraulic brakes have a 12 volt fan forcing cool air from outside the engine compartment onto the brake components to protect the system from overheating Overheating can damage the hydraulic brake components Make sure the brake cooling fan is operating when the vehicle is being driven The fan operates when the ignition switch is in the run position Keep the brake cooling system in good working order by e cleaning debris from the air intake screen and ducts e keeping electrical connections tight and components securely mounted Ontario Drive amp Gear Limited PH 519 662 2840 FAX 519 662 2421 BR www odg com Argo Service Manual Brake System Supplement Pages Ontario Drive amp Gear ltd www odg com centaur 519 662 2840 FAX 519 662 2421 o 6x6Wonid comi Gaon Wir Leorn Argo Service Manual Brak
57. will be located between the 2 steering arms iv Install the second steering arm and last spring pin Photo ST 15 Orient as in Photo ST 16 Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 BR 4A Argo Service Manual Brake Steering System 9 Apply some axle grease to the length of the Steering Shaft Photo ST 17 and insert it from the bottom up into the Steering Column Assembly with the small keyway facing towards you Photo ST 18 1 Re attach the 612 117 Steering Column Frame Assembly to the transmission Secure with 2 103 55 fasteners and 2 108 24 Washers at the front 2 locations and 1 112 132 longer fastener and 1 108 24 Washer at the rear location Photo ST 18A IMPORTANT Remember to reinstall the 108 08 Flat Washers between the steering column frame assembly plate and transmission mounting bosses Refer to your illustrated parts manual to review their location if necessary Ontario Drive amp Gear Limited BR SA www odg com PH 519 662 2840 FAX 519 662 2421 VA Brake Steering System Argo Service Manual 10 Place the key to the end of the Steering Shaft Photo ST 19 Vehicles manufactured from serial numbers N14990 V23535 R23560 A15022 utilize 2 keyways and 2 keys 11 Align the keyway s of the Lower Handle Bar Clamp with that of the previously installed key s and assemble to the Steering Shaft Photo ST 20 amp 21 12 Install a Flat Wa
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