BODY ROLL ON 2002

The 02 ACT 375-500 shocks have both a softer spring and a softer dampening rate, if you like a ride as smooth as a Lincoln Continental the 02's are wonderful, but you have to live with increased body roll. However if you are willing to give up just a little of that super soft ride the 01 shocks and springs will bolt right on the 02's and reduce a great deal of the body roll, oh and if you want an even stiffer ride just install "Cowboys" 1/2" spring spacers on those 01 shocks, but don't try the spacer trick on the 02's front shocks the valving is to soft and the shock will "top out"

Front: shock&spring p/n's 0403-001 & 0403-002
Rear: shock&spring p/n's 0404-001 & 0404-006


BRAKES:

There are 3 things going on with the brakes on some 02's

#1 There was/is a recall on the brake pressure switch on the

300-500 4x4 & 375 2x4 s/n 208931 - 227537
Your dealer can replace it in just a few minuets.

#2 This is a good one because it actually took the manufacture
( not AC ) of the master cylinder extra time to screw it up.
The bore of the cylinder where the piston goes in&out was honed
to a polished finish the problem is the cylinder actually needs
just a little cross hatch so that the brake fluid can lubricate
the o-rings on the piston. With a smooth bore it just wipes the
o-rings dry and then the piston won't travel freely and you get
a short stroke of the piston and the brakes don't fully apply.

#3 This is an easy one and will really make your brakes work, there
is a vent hole in the outside edge of the master cyl. cap. This
vent keeps a vacuum from forming in the bladder (that big rubber
thing under the cap) the problem is this vent may get pluged
with mud or other crap or the rubber bladder may just swell
enough to plug the vent. The solution is simple just remove the
M.S. cap and drill a 0.040" or # 60 drill bit hole in the
center of the cap then make sure there are no burrs around
the hole that would damage the bladder then reinstall the cap.


The vent hole trick will work on other brands of wheelers also just remember to hold on tight or you might find yourself over the front of the handle bars.


hope this helps

 

CaTTrax, Thanks for the Info. My 500i auto was not part of the pressure switch recall. But when I called the factory they said there was a service bulletin out on mine to replace the whole master cylinder. I asked why and the only info. she gave me was that it did not meet AC's standards and I should contact the dealer. I called my dealer he is still trying to get me the details .Do you have any Info. about this bulletin? She said the bulletin # is 2002-12.

 

Will item #3 work on the 01 models too? I also noticed that the 02 models have stainless steel brake lines. Do you know if there is an upgrade kit for the 01 models?

 

ttaylor, To my knowledge only the "i" models have the stainless steel brake lines I am not sure if a retro fit is available.

 

Crazy Cat
the service bulletin is 2002-2-12 it covers 2002 mod. 300 4x4, 400i 4x4
500i auto & man
500 tbx

the new part # 0502-351
I have had this problem with other models that are not listed in this S.B. so... if you do, I would talk to your dealer.



TTaylor
Yes #3 works on all models as well as other brands. Just make sure you remove the cap before you drill so you don't put a hole in the bladder.

 

CaTTrax, The "problem" you are talking about is that your BRAKES #2 post above.If not can you elaborate on the problem. Also do you no if the new replacement part is available for shipping yet. Thank-you for your Help!

 

CrazyCat
Yes the M.S. is available or it was last week anyway.

Yes the info in #2 is the reason for the M.S. change.

Have a GOOD Weekend!

 

CaTTrax, that sure sound's like a lot of info. You sure sound like a dealer or something.

BTW, I am not sore with you anymore. We all feel like we need to be taken care of at times.

Some good info.

 

Cattrax thanks for the headsup on the Mastercylinder. I believe my vent hole closes off occasionally. I had trouble getting sufficient braking power on several occasions. I changed the recall pressure switch and opened the M.C. which allowed air into the M.C. Brakes work great. I think the casting tolerance vary to the point the hole won't let the rubber bladder breath. By the way the 2002 500 (nonI) has rubber brake lines.