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Unread 08-13-2016, 08:50 AM   #1
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Default Ausco cable disc brake install thread

The Ausco cable operated disc brake kit has been very popular.
In this instructional thread I will document the install of PK2017 and cable shield extensions PK2020.
The subject cart is a 2010 Ezgo TXT48. This kit fits a variety of Ezgo year and model carts dating back to 1985 or so... basically if the Ezgo cart has a single axle nut kit PK2017 will fit.
Currently the lowest price on the internet for Ausco HD hubs and brake kits is here > http://www.cartsunlimited.net/ausco-products.html

In order to keep on track as an informational thread. Please start a new thread if you have a problem you need help solving.
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Unread 08-13-2016, 11:54 AM   #2
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Default Re: Ausco cable disc brake install thread

This is an install thread only. If you are having trouble with stopping or have a fitment or install problem, or want to discuss a different product ... please start a new thread. Thank you for helping me keep on track.

This content should help you decide if cable disc brakes is something you want to add to your cart. You will see exactly what the install involves and what tools are needed. This upgrade took me about 1 hour to complete.

This is a level 2 install. For a complete description of my 1-4 install difficulty levels go here > http://www.cartsunlimited.net/instal...ng-system.html

Note the Disc Brake assembly requires a 10 inch wheel with a minimum 9.25 inches in the clear. Not all 10" wheels have enough clearance. Ask your dealer to verify if the wheels you are looking to purchase have the required clearance.


Okay - Lets get started
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Unread 08-13-2016, 12:39 PM   #3
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Default Re: Ausco cable disc brake install thread

What's in the box?
1 side shown.
Box contains 2 of everything
2 HD hubs. These are the same HD repair hubs you see in PK2127.
These hubs will not strip out like OEM drums. That's a nice bonus
2 rotors
2 caliper assembly & bracket.
Lets get to work
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Unread 08-13-2016, 01:05 PM   #4
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Default Re: Ausco cable disc brake install thread

Always remember safety first.
Bust the rear lug nuts loose with a 2 ft breaker bar or equivalent power source.
Just a 1/4 to a half turn will do it.
Jack the cart up and put the rear on jack stands.
If you opt not to use stands remove the wheel and put it under the cart, lined up so it under the frame rail close to the work area.
That will give 8" to live should the jack fail.

Remove the cotter pin and 15/16 axle nut. The nut is torqued to 90-140 ft pounds - so you should need that breaker bar again. If setting the park brake does not hold the drum then get a longish bar and place it between the hub center and lug studs (see pic) to stop rotation.

Remove the cable end cotter pin and clevis. Keep these parts. You will reuse them.
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Unread 08-13-2016, 01:21 PM   #5
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Default Re: Ausco cable disc brake install thread

Notice the TXT48 has the brake cable on top of the axle. Earlier years TXT and Marathon all had the cable below the axle. The caliper bracket is U shaped. For this cart the U will be right-side up and in earlier yrs it will be up side down.

I'm getting ahead of the work - remove the C clip retaining the brake cable sheath at the mounting OEM bracket. KEEP this clip, you will reuse it.

Remove the four break backing plate bolts and remove the backing plate and cable mount bracket. That sounds easy and it should be but, they are on there tight & in some cases these bolts are rusty or worse. Worse case scenario - you may need to replace the bolts. I never have had to in all my yrs as a tech. God blessed the southwest with an almost rust free environment. If you do replace them use hardened bolts as they hold the caliper in place here.

____________________________________________


Once the backing plate & cable mount is removed, grab hold of an end of the cable spring and pull it out and away - removing the spring from the cable.

On the bench, remove the mounting bracket from the caliper assembly using a 9/16 wrench and 7/32 hex head wrench or equivalent.
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Unread 08-13-2016, 01:35 PM   #6
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Default Re: Ausco cable disc brake install thread

Install the caliper bracket on the axle tube flange where the backing plate was mounted using the same 4 bolts (1/2" socket and wrench) you removed. If the nuts need replacing Please use hardened bolts not fence bolts. Not inferior, left over Chinese hardware. Bolt failure could be serious. Tighten these bolts up good. Note OEM bolts have self locking nuts. Many types of self locking nuts are available, I prefer the stamped or slightly squished type for this application.

Once the flange is mounted, apply a light coat of never-cease to the axle splines and install the HD hub. Torque the nut to 100 pounds (min.) or more as needed to line up with the cotter pin hole. NEVER back the nut off to line up the cotter pin hole. Always go a little tighter, which is why the spec is 90-140 ft. pounds.

Slide the rotor / hub over the lug bolt studs and loosely secure with 1 or 2 lug nuts. Hand tight is all that is needed.

Next place the caliper assembly over the mounting bracket as shown in your directions. If actual install I encourage you to following the instructions. It has great pics for dummies, like us.

Pay attention to the spacers you removed to separate the caliper mounting bracket. There are 2 long and 2 short tubular spaces for each side of the cart. Place a long spacer over the 2 bolts as shown below insert these through the RED brake pads and mounting bracket. Slide the short tubes on the threaded end of the bolt. NOW- wiggle the bolts and spacer a bit until the sleeves seat and there is about 1/2" of thread showing for the nut.

IF 1/4" of thread is showing a spacer is hung up and not seated in it's hole. IMPORTANT 1/2" of thread should be showing for the 9/16ths lock nut to be put on. Install the nuts and rotate the rotor by hand to insure it moves freely.
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Unread 08-13-2016, 02:07 PM   #7
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Default Re: Ausco cable disc brake install thread

Cable attachment. The brake cable adjustment will need to be loosened.
Again my northern and southeastern friends tell me the double nut and threaded rod assembly rusts and makes adjustment difficult.... They suggest removing the assembly and cleaning the rust off of it. Here in the SW we use this time to get another cold drink. It's hotter than blazes in August here.

Use 2 wrenches (1/2" and 5/8") to loosen the lock nut on the end of the adjustment rod at the brake cable equalizer.
Pull this assembly downward enough to get a ratchet and deep well 1/2 socket or better a small impact driver on it.
I use three size battery impact drivers for my work, they really make the work easier & speed things up.

Put the cable sleeve into the new silver cable holder and reinstall the C clip you kept from the original brakes. Pull enough additional length of cable (by way of loosening the adjustment) to line up the cable end holes and the actuator arm hole. Insert the clevis pin and insert the cotter pin (both saved from original brakes)
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Unread 08-13-2016, 02:34 PM   #8
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Default Re: Ausco cable disc brake install thread

Put a wheel on and check clearance by rotating the tire by hand. I used a 10x7 205-50-10 tire and wheel assembly which did not require a lift kit. Kind of an old school look.

Repeat the whole process for the other side. It should be easier
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Unread 08-13-2016, 02:40 PM   #9
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Default Re: Ausco cable disc brake install thread

For lifted carts you may want to add PK2020 cable extenders. These are actually cable sheath spacers or extenders. The online instruction failed to show a good picture of how these were installed but the instructions that come with the kit cover it well.
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Unread 08-13-2016, 02:48 PM   #10
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Default Re: Ausco cable disc brake install thread

Once the install is complete adjust the brake cables at the equalizer until the park brake catches and go for a low speed test. Readjust as needed by following the brake test and adjustment instruction in your install material.

The cart stops quicker and smoother than ever.


Thanks for following along. I hope this helps.

Find the low price Ausco products here > http://www.cartsunlimited.net/ausco-products.html
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