Parking Brake Cable: Service and Repair
NOTE: Before proceeding with this procedure, review all Service Warnings And Cautions found under Service Precautions.
To service either parking brake cable, proceed as follows:
REMOVAL
1. Disconnect the (-) negative cable from the battery and isolate the cable from the battery.
2. Remove the 6 screws on each side of the vehicle attaching the driver and passenger side lower fascias to the instrument panel. Then remove both fascia panels from the vehicle.
3. Remove the screw mounting the ash tray to the console. Then remove the ash tray from the console.
4. Remove the bezel for the heater/air conditioning controls and radio from instrument panel. Remove bezel by carefully prying out of the instrument panel and console using a screw driver.
5. Disconnect the wiring harness connectors from the lighter and fog lamp switches located in the bezel. Then remove bezel from vehicle.
6. Remove the 2 screws, one on each side of the console, attaching the rear of the console assembly to the tunnel of the vehicle.
NOTE: The driver and passenger seat need to be in the full rear position to gain access to the screws.
7. Pull park brake lever up as far as it will go. Lift console assembly up from the rear while sliding park brake boot off park brake lever, to gain access to shift knob attaching nut. Hold shift knob with one hand and loosen nut. When nut is loose turn shift knob off shifter.
8. Lift the console assembly with shift knob and boot attached, off the tunnel.
WARNING: THE SELF-ADJUSTING FEATURE OF THIS PARKING BRAKE LEVER ASSEMBLY CONTAINS A CLOCK SPRING LOADED TO APPROXIMATELY 30 POUNDS. CARE MUST BE TAKEN TO PREVENT EXCESSIVE JARRING OF THE ASSEMBLY. DO NOT RELEASE THE SELF ADJUSTER LOCKOUT DEVICE BEFORE INSTALLING CABLES INTO THE EQUALIZER. KEEP HANDS OUT OF SELF ADJUSTER SECTOR AND PAWL AREA. FAILURE TO OBSERVE CAUTION IN HANDLING THIS MECHANISM COULD LEAD TO SERIOUS INJURY.
9. Load and lockout the parking brake lever self adjuster mechanism using the following procedure:
a) Insert a 7/32 inch allen wrench into the allen head screw of the lockout device.
b) Pull on the equalizer/output cable to wind up adjuster spring (requires greater than 30 pounds effort).
c) Pull up on cable until self-adjuster lockout pawl is positioned about midway on the self-adjuster sector.
d) Rotate the lockout device pawl into self adjuster sector by turning allen screw clockwise.
10. Remove both rear park brake cables from the equalizer.
11. To remove park brake cable from tunnel proceed as follows:
a) Install a wrench of the appropriate size to compress the retaining tabs on the cable retainer.
b) Push on end of cable keeping wrench against support plate in tunnel until retainer tabs are out past tunnel area.
12. Raise vehicle. See Hoisting in Maintenance for the required lifting procedure.
13. From under vehicle, remove cable requiring service out of tunnel area of vehicle.
NOTE: If the left park brake cable is being replaced, it is only clipped to the rear frame rail and not to the frame crossmember. The left park brake cable is held in place at the crossmember by the differential. The differential will need to be lowered enough to remove the park brake cable from between the differential and crossmember.
14. Remove the 2 clips attaching the parking brake cable to the frame crossmember and rear frame rail.
15. Remove the tie strap attaching the park brake cable to rear knuckle.
16. Remove the parking brake cable from the park brake operating lever on the caliper. Slide parking brake cable out of cable mounting hole in caliper assembly.
INSTALLATION
1. Insert end of parking brake cable into mounting hole in caliper assembly. Hook end of parking brake cable into parking brake operating lever on caliper assembly.
NOTE: When routing the parking brake cable at the knuckle, the cable must be routed between the upper ball joint castle nut and the knuckle.
2. Route the parking brake cable along the knuckle and install the tie strap attaching the park brake cable to the knuckle.
3. Correctly route the parking brake cable from the caliper to the tunnel panel.
4. Install parking brake cable into tunnel panel. Insert park brake cable into tunnel panel hole until retainer tabs are expanded out past support plate. Pull on cable to ensure it is locked into tunnel panel.
NOTE: If the left park brake cable is being replaced it is only clipped to the rear frame rail and not to the frame crossmember. The left park brake cable is held in place at the crossmember by the differential. If the replacement park brake cable has a clip installed for attaching it to the crossmember remove the clip from the cable.
5. Install the 2 clips attaching the parking brake cable to the frame crossmember and rear frame rail.
6. Lower vehicle.
7. Install rear parking brake cables into equalizer on park brake mechanism. Be sure the lugs on the end of the cables are squarely seated against the equalizer.
8. Unload and adjust parking brake cables. To do so, insert a 7/32 inch allen wrench into hex socket and turn counterclockwise through approximately 15° of rotation. In turning lockout device, a loud snapping noise followed by a more felt than heard detente should be realized. Very light effort is required to seat the lockout arm into detente. Very light effort is required to seat lockout arm into detente.
NOTE: Following through to the detente is important in preventing the lockout rod from rattling.
9. Operate park brake mechanism several times to ensure proper operation. Also be sure that the rear park brake cables are not binding when released.
10. Install the console assembly and park brake lever boot over park brake lever. Then install console assembly on tunnel area of vehicle, with the rear of the console positioned as high as possible.
11. Thread shift knob onto shifter until their is adequate thread engagement, and knob is correctly positioned. Securely tighten the shift knob to shifter retaining jam nut.
12. Lower the console assembly onto the tunnel until correctly positioned in the vehicle. Align the console assembly screw holes with holes in tunnel and install and securely tighten the 2 screws.
13. Connect wiring harness connectors to the fog lamp switches and lighter assembly on the bezel. Be sure the connectors are fully installed on terminals.
14. Align mounting clips on heater, radio and console bezel, with clip attaching holes in instrument panel and console assembly. Carefully push or tap around edge of bezel, until all bezel mounting clips are locked into instrument panel and console assembly.
15. Install ash tray assembly into opening in bezel. Install the ash tray assembly to console assembly attaching screw and securely tighten.
16. Install driver side and passenger side lower instrument panel fascias. Install the 6 screws attaching each lower fascia to the instrument panel and tunnel of vehicle.
17. Reconnect the (-) negative battery cable to the negative battery post. Reset any electrical components on vehicle affected by disconnecting the battery.