Locking CHRYSLER VOYAGER 2005 Service Manual

LATCHING TYPE BOOT CLAMP
If seal boot uses low profile latching type boot
clamp, use the following procedure to install the
retaining clamp.
(1) Place prongs of clamp locking tool in the holes
of the clamp (Fig. 25).
(2) Squeeze tool together until top band of clamp is
latched behind the two tabs on lower band of clamp
(Fig. 26).
(14) Install the half shaft back into the vehicle.
(Refer to 3 - DIFFERENTIAL & DRIVELINE/HALF
SHAFT - INSTALLATION)
CV BOOT - OUTER
REMOVAL
(1) Remove halfshaft assembly requiring boot
replacement from vehicle. (Refer to 3 - DIFFEREN-
TIAL & DRIVELINE/HALF SHAFT - REMOVAL)
(2) Remove large boot clamp retaining C/V joint
sealing boot to C/V joint housing (Fig. 27) and dis-
card. Remove small clamp that retains outer C/V
joint sealing boot to interconnecting shaft and dis-
card. Remove sealing boot from outer C/V joint hous-
ing and slide it down interconnecting shaft.
(3) Wipe away grease to expose outer C/V joint and
interconnecting shaft.
(4) Remove outer C/V joint from interconnecting
shaft using the following procedure: Support inter-
connecting shaft in a vise equipped with protective
caps on jaws of vise to prevent damage to intercon-
necting shaft. Then, using a soft±faced hammer,
sharply hit the end of the C/V joint housing to dis-
lodge housing from internal circlip on interconnecting
shaft (Fig. 28). Then slide outer C/V joint off end of
interconnecting shaft, joint may have to be tapped off
shaft using asoft±facedhammer.
(5) Remove large circlip (Fig. 29) from the inter-
connecting shaft before attempting to remove outer
C/V joint sealing boot.
(6) Slide sealing boot off interconnecting shaft.
(7) Thoroughly clean and inspect outer C/V joint
assembly and interconnecting joint for any signs of
excessive wear.If any parts show signs of exces-
sive wear, the halfshaft assembly will require
replacement. Component parts of these half-
shaft assemblies are not serviceable.
Fig. 25 Clamping Tool Installed on Sealing Boot
Clamp
1 - CLAMP
2 - TOOL YA3050, OR EQUIVALENT
3 - SEALING BOOT
Fig. 26 Sealing Boot Clamp Correctly Installed
1 - INNER TRIPOD JOINT HOUSING
2 - TOP BAND OF CLAMP MUST BE RETAINED BY TABS AS
SHOWN HERE TO CORRECTLY LATCH BOOT CLAMP
3 - SEALING BOOT
Fig. 27 Outer C/V Joint Seal Boot Clamps
1 - SMALL CLAMP
2 - SEALING BOOT
3 - OUTER C/V JOINT HOUSING
4 - LARGE CLAMP
5 - INTERCONNECTING SHAFT
3 - 10 HALF SHAFT - FRONTRS
CV BOOT - INNER (Continued)

shoes on the opposite side of the vehicle as well as
the shoes failing inspection.
If the brake shoe assemblies do not require
replacement, be sure to reinstall the brake shoes in
the original position they were removed from.
INSTALLATION - REAR DISC BRAKE SHOES
(1) Completely retract caliper piston back into pis-
ton bore of caliper assembly.
(2) Lubricate both adapter abutments where the
shoes contact with a liberal amount of MopartMul-
tipurpose Lubricant, or equivalent.
(3) If removed, install the brake rotor on the hub,
making sure it is squarely seated on the face of the
hub.
(4) Install the inboard brake shoe into the caliper
piston by firmly pressing it into the piston bore using
your thumbs. Be sure inboard brake shoe is posi-
tioned squarely against the face of the caliper piston.
NOTE: The outboard shoes are different left to
right. They can be identified by a L or R stamped on
the clip.
(5) Install the outboard brake shoe on the disc
brake caliper. Be sure the outboard shoe is positioned
squarely against the outboard fingers of the caliper.
CAUTION: Use care when installing the caliper
assembly onto the adapter, so the caliper guide pin
bushings do not get damaged by the mounting
bosses.
(6) Carefully lower caliper and brake shoes over
rotor and onto adapter, reversing the removal proce-
dure (Fig. 15).
CAUTION: When installing the caliper guide pin
bolts extreme caution should be taken not to
crossthread the guide pin bolts.
(7) Install the caliper guide pin bolts. Tighten the
guide pin bolts to a torque of 35 N´m (26 ft. lbs.).
(8) Install the wheel and tire assembly. Tighten
the wheel mounting nuts in proper sequence until all
nuts are torqued to half specification. Then repeat
the tightening sequence to the full specified torque of
135 N´m (100 ft. lbs.).
(9) Lower vehicle.
CAUTION: Before moving vehicle, pump the brake
pedal several times to insure the vehicle has a firm
brake pedal to adequately stop the vehicle.
(10) Pump brake pedal several times to set brake
shoes to rotors.
(11) Check fluid level in reservoir.(12) Road test the vehicle and make several stops
to wear off any foreign material on the brakes and to
seat the brake shoe linings.
BRAKE PADS/SHOES - REAR
DRUM
REMOVAL - REAR DRUM BRAKE SHOES
(1) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE).
(2) Remove the rear wheel and tire assemblies
from the vehicle.
(3) Remove rear brake drum to hub retaining clips
(if equipped), then remove rear brake drums. (Refer
to 5 - BRAKES/HYDRAULIC/MECHANICAL/DRUM
- REMOVAL)
NOTE: When creating slack in the park brake cables
by locking out the automatic adjuster, (Fig. 18) be
sure that the park brake pedal is in the released
(most upward) position.
(4) Create slack in the rear park brake cables.
Slack is created by grabbing exposed section of front
park brake cable and pulling it down and rearward.
Slack is maintained in the park brake cable by
installing a pair of locking pliers on the park brake
cable just rearward ofonly the rearbody outrigger
bracket. (Fig. 18)
Fig. 18 Locked Out Park Brake Automatic Adjuster
1 - PARK BRAKE CABLE
2 - REAR BODY OUTRIGGER BRACKET
3 - LOCKING PLIERS
RSBRAKES - BASE5-19
BRAKE PADS/SHOES - REAR DISC (Continued)

(3) Install the park brake actuator strut (Fig. 30)
on the leading brake shoe. Then install the park
brake actuator lever on the strut (Fig. 30).
(4) Install the automatic adjuster screw on the
leading brake shoe. Then install the trailing brake
shoe on the park brake actuating lever and park
brake actuating strut (Fig. 26). Position trailing
brake shoe on brake support plate.
(5) Install the brake shoe hold down pin and
spring on the trailing brake shoe (Fig. 25).
(6) Install the brake shoe to brake shoe upper
return spring (Fig. 24).
CAUTION: When installing the tension clip on the
automatic adjuster, it must be located on only the
threaded area of the adjuster assembly (Fig. 23). If it
is located on a non-threaded area of the adjuster, the
function of the automatic adjuster will be affected.
(7)Install the tension clip (Fig. 23) attaching the
upper return spring to the automatic adjuster assembly.
(8)Install the brake shoe to brake shoe lower return
springs on the brake shoes (Fig. 21) and (Fig. 22).
(9) Install automatic adjustment lever on the lead-
ing brake shoe of the rear brake assembly (Fig. 20).
(10) Install the actuating spring on the automatic
adjustment lever and leading brake shoe assembly
(Fig. 19).
(11) Verify that the automatic adjuster lever has
positive contact with the star wheel on the automatic
adjuster assembly.
(12) When all components of both rear brake
assemblies are correctly and fully installed, remove
the locking pliers from the front park brake cable.(13) Adjust brake shoes assemblies so as not to
interfere with brake drum installation.
(14) Install the rear brake drums on the hubs.
(15) Adjust rear brake shoes.
(16) Install the wheel and tire assembly.
(17) Tighten the wheel mounting stud nuts in
proper sequence until all nuts are torqued to half
specification. Then repeat the tightening sequence to
the full specified torque of 135 N´m (100 ft. lbs.).
(18) Lower the vehicle.
(19) Push the parking brake lever (pedal) to the
floor once and release pedal. This will automatically
remove the slack from and correctly adjust the park-
ing brake cables.
(20) Road test vehicle. The automatic adjuster will
continue the brake adjustment during the road test
of the vehicle.
ADJUSTMENTS
ADJUSTMENT - REAR DRUM BRAKE SHOES
NOTE: Normally, self-adjusting drum brakes do not
require manual brake shoe adjustment. Although, in
the event of a brake shoe replacement, it is advis-
able to make the initial adjustment manually to
speed up the adjusting time.
NOTE: Before raising the vehicle, verify the parking
brake lever is fully released.
(1) Raise the vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE).
(2) Remove rubber plug from rear brake adjusting
hole in the rear brake support plate.
(3) Insert a thin screwdriver through the adjusting
hole in the support plate and against the star wheel
of the adjusting screw. Move handle of the tool down-
ward, rotating the star wheel until a slight drag is
felt when tire and wheel assembly is rotated.
(4) Insert a second thin screwdriver or piece of
welding rod into brake adjusting hole and push the
adjusting lever out of engagement with the star
wheel.Care should be taken so as not to bend
adjusting lever or distort lever spring.
(5) While holding the adjusting lever out of
engagement, back off the star wheel just enough to
ensure a free wheel with no brake shoe drag.
(6) Repeat the above adjustment at the other rear
wheel.
(7) Install the adjusting hole rubber plugs back in
the rear brake support plates.
(8) Lower the vehicle.
Fig. 30 Park Brake Components Assembled On
Leading Brake Shoe
1 - PARK BRAKE CABLE
2 - LEADING BRAKE SHOE
3 - PARK BRAKE ACTUATING STRUT
4 - PARK BRAKE ACTUATING LEVER
5 - BRAKE SUPPORT PLATE
RSBRAKES - BASE5-23
BRAKE PADS/SHOES - REAR DRUM (Continued)

Vehicles with Fold-in-floor seating have three flex-
ible steel parking brake cables. They are:
²Front
²Left rear
²Right rear
The front parking brake cable extends from the
parking brake lever. A steel equalizer bracket con-
nects the front parking brake cable to the left rear
and intermediate cables on vehicles without Fold-in-
floor seating. The equalizer bracket connects the
front parking brake cable to the left rear and right
rear cables on vehicles with Fold-in-floor seating. The
intermediate cable is connected to the right rear
cable on vehicles without Fold-in-floor seating. A
standard cable connector is used to accomplish this
connection.
On vehicles equipped with rear drum brakes, the
rear service brakes also act as the vehicle's parking
brakes.
Vehicles equipped with rear disc brakes use a
small duo-servo brake assembly mounted to the each
rear disc brake caliper adapter as the parking brake.
The inside of the brake rotor (hat section of drum-in-
hat style brake rotor) is used as the parking brake
drum.
DESCRIPTION - EXPORT
The parking brake system on this vehicle features
a hand-operated parking brake lever. The lever is
located between the two front seats and requires a
special front cable.
OPERATION
The automatic-adjusting feature in the foot oper-
ated parking brake lever continuously applies mini-
mal tension to the parking brake cables when the
parking brake lever is in the released position to
keep them in adjustment at all times. Due to this
feature, the parking brake cables require no periodic
adjustment.
When the parking brake lever is applied, the
cables are pulled, thus applying the brake shoes
(rear drum brakes) or parking brake shoes (rear disc
brakes) at each rear wheel.
The brake shoes are mechanically operated by an
internal lever and strut connected to the rear park-
ing brake cables.
An equalizer bracket is used at the rear end of the
front parking brake cable to distribute tension
equally to each parking brake cable.
STANDARD PROCEDURE
STANDARD PROCEDURE - PARKING BRAKE
AUTOMATIC ADJUSTER TENSION RELEASE
The parking brake lever (pedal) mechanism used
in this vehicle is designed so that the automatic
adjuster is not required to be locked out when servic-
ing the parking brake lever (pedal) or the parking
brake cables.
This parking brake lever (pedal) mechanism is
designed so that the adjuster mechanism will rotate
only half a turn when the tension is released from
the parking brake cable. This eliminates the require-
ment to lock out the automatic adjuster when servic-
ing the parking brake lever (pedal) mechanism and
cables.
Use the following procedure to release the tension
from the parking brake cables and the automatic
adjuster in the parking brake lever (pedal) mecha-
nism.
(1) Release the parking brake.
(2) Raise and support the vehicle. (Refer to
LUBRICATION & MAINTENANCE/HOISTING -
STANDARD PROCEDURE)
(3) If equipped with Fold-in-floor seating, perform
the following:
(a) Clamp an appropriate pair of locking pliers
on the front parking brake cable strand approxi-
mately 25 mm (1 inch) forward of the button at the
equalizer (Fig. 95).
Fig. 95 Location To Grasp Cable At
RSBRAKES - BASE5-63
PARKING BRAKE (Continued)

(b) Grasp the equalizer and pull rearward on it
until enough slack is present to disconnect the
equalizer from front or rear cables. While holding
the front cable in this position using the locking
pliers, disconnect the equalizer from cables (Fig.
96).
(c) Ease up on the front cable tension allowing
the lever automatic self-adjusting mechanism to
pull the front cable strand forward. This action
allows the adjuster mechanism to rotate around to
its stop, removing tension from the adjuster and
front parking brake cable.
(d) Remove the locking pliers from the front
parking brake cable as necessary.
(4) If not equipped with Fold-in-floor seating, per-
form the following:
(a) Grasp the exposed section of the front park-
ing brake cable and pull rearward on it.
(b) While holding the cable in this position,
(c) Clamp an appropriate pair of locking pliers
on the front parking brake cable strand just rear-
ward of the second body outrigger bracket (Fig.
97).
(d) Disconnect the parking brake cables from the
parking brake cable equalizer (Fig. 98).
(e) Remove the locking pliers from the front
parking brake cable as necessary. This action
allows the adjuster mechanism to rotate around to
its stop, removing tension from the adjuster and
front parking brake cable.
STANDARD PROCEDURE - PARKING BRAKE
AUTOMATIC ADJUSTER TENSION RESET
NOTE: This procedure is designed for vehicles
without Fold-in-floor seating.
The parking brake lever (pedal) mechanism used
in this vehicle is designed so that the automatic
adjuster is not required to be locked out when servic-
ing the parking brake lever (pedal) or the parking
brake cables.
(1) Grasp the exposed section of the front parking
brake cable and pull rearward on it. While holding
Fig. 96 Parking Brake Cable Equalizer
1 - INTERMEDIATE BRACKET
2 - EQUALIZER
3 - LEFT REAR CABLE
4 - RIGHT REAR CABLE
5 - FRONT CABLE
Fig. 97 Locking Out Automatic Adjuster
1 - PARK BRAKE CABLE
2 - REAR BODY OUTRIGGER BRACKET
3 - LOCKING PLIERS
Fig. 98 Parking Brake Cable Attachment To
Equalizer
1 - EQUALIZER
2 - LEFT REAR PARKING BRAKE CABLE
3 - LOCKING NUT
4 - INTERMEDIATE PARKING BRAKE CABLE
5 - FRONT PARKING BRAKE CABLE
5 - 64 BRAKES - BASERS
PARKING BRAKE (Continued)

the park brake in this position, install a pair of lock-
ing pliers on the front parking brake cable just rear-
ward of the second body outrigger bracket (Fig. 97).
(2) Install the equalizer on the front parking brake
cable.
(3) Install the left rear and intermediate park
brake cable in the correct location on the parking
brake cable equalizer (Fig. 98).
(4) Remove the locking pliers from the front park-
ing brake cable. This will allow the adjuster in the
park brake lever (pedal) mechanism to tension the
park brake cables.
(5) Apply and release the parking brake lever
(pedal) one time. This will seat the parking brake
cables and allow the auto adjuster in the parking
brake lever (pedal) mechanism to correctly tension
the parking brake cables.
STANDARD PROCEDURE - CABLE END
CLEANING AND LUBRICATION
Periodic cleaning and lubrication can be done to
ensure proper operation of the parking brake cables.This procedure applies to the trailing end of all park-
ing brake cables.
CAUTION: If a liquid cleaner is necessary, use a
cleaner such as MoparTNon-Chlorinated Brake
Parts Cleaner or equivalent.
(1) Using an appropriate bristle brush, clean the
cable strand in the area that retracts into the cable
housing when the parking brake lever is applied (Fig.
99).
(2) Clean the cable seal area at the end of the
cable housing (Fig. 99).
(3) Lubricate the cleaned area with a general pur-
pose grease lubricant.
ADJUSTMENTS
ADJUSTMENT - PARKING BRAKE CABLES
The park brake cables on this vehicle have an
automatic self adjuster built into the park brake
pedal mechanism. When the foot operated park brake
pedal is in its released (upward most) position, a
clock spring automatically adjusts the park brake
cables. The park brake cables are adjusted (ten-
sioned) just enough to remove all the slack from the
cables. The automatic adjuster system will not over
adjust the cables causing rear brake drag.
Due to the automatic adjust feature of the park
brake pedal, adjustment of the parking brake cables
on these vehicles relies on proper drum brake and
park brake shoe adjustment. (Refer to 5 - BRAKES/
HYDRAULIC/MECHANICAL/DRUM - ADJUST-
MENTS) and (Refer to 5 - BRAKES/PARKING
BRAKE/SHOES - ADJUSTMENTS).
When the park brake pedal is applied the self
adjuster is by-passed and the pedal operates nor-
mally to engage the park brakes.
When a service procedure needs to be performed on
the park brake pedal or the park brake cables, the
automatic self adjuster can be manually locked out
by the service technician.
Fig. 99 Areas To Be Cleaned And Lubricated
1 - STRAND AREA
2 - SEAL AREA
RSBRAKES - BASE5-65
PARKING BRAKE (Continued)

CABLE - PARKING BRAKE
FRONT
REMOVAL
REMOVAL
(1) Raise and support the vehicle. (Refer to
LUBRICATION & MAINTENANCE/HOISTING -
STANDARD PROCEDURE).
(2) Manually release the automatic self-adjusting
mechanism tension of the parking brake lever (pedal)
assembly. (Refer to 5 - BRAKES - STANDARD PRO-
CEDURE).
(3)
Remove the intermediate and left rear park brake
cable from the park brake cable equalizer (Fig. 100).
(4) Remove the front park cable housing retainer
from body outrigger bracket (Fig. 101). Cable is
removable by sliding a 14 mm box wrench over cable
retainer and compressing the three retaining fingers.
Alternate method is to use an aircraft type hose
clamp and screwdriver.
(5) Lower vehicle.
(6) Remove the left front door sill molding.
(7) Remove the left front kick panel for access to
the park brake cable and park brake pedal assembly.
(8) Lift floor mat for access to park brake cable
and floor pan. Pull the seal and the park brake cable
(Fig. 102) out of the floor pan of vehicle.
(9) Pull parking brake cable strand end forward
and disconnect button from clevis. Tap cable housing
end fitting out of pedal assembly bracket.
(10) Remove cable retainer from the parking brake
lever (pedal) assembly bracket.(11) Pull front parking brake cable assembly out of
vehicle through hole in floor pan.
REMOVAL - FOLD-IN-FLOOR SEATING
(1) Release the parking brake.
(2) Raise and support the vehicle. (Refer to
LUBRICATION & MAINTENANCE/HOISTING -
STANDARD PROCEDURE)
(3) Manually release the automatic self-adjusting
mechanism tension of the parking brake lever (pedal)
assembly. (Refer to 5 - BRAKES - STANDARD PRO-
CEDURE).
Fig. 100 Park Brake Cable Attachment To Equalizer
1 - EQUALIZER
2 - LEFT REAR PARKING BRAKE CABLE
3 - LOCKING NUT
4 - INTERMEDIATE PARKING BRAKE CABLE
5 - FRONT PARKING BRAKE CABLE
Fig. 101 Front Park Brake Cable Attachment To
Body
1 - CABLE HOUSING RETAINER
2 - BODY OUTRIGGER BRACKET
3 - PUSH WRENCH OVER END OF RETAINER HERE
4 - FRONT PARK BRAKE CABLE
Fig. 102 Front Park Brake Cable At Floor Pan
1 - PARK BRAKE PEDAL ASSEMBLY
2 - PARK BRAKE PEDAL
3 - CARPET
4 - FRONT PARK BRAKE CABLE
5 - SEAL
6 - FLOOR PAN
5 - 66 BRAKES - BASERS

(4) Remove the front cable from the equalizer (Fig.
103).
(5) Remove the locking pliers from the cable that
were installed during Step 3.
(6) Remove the front cable from the routing clips
fastened to the underbody of the vehicle (Fig. 104).(7) Place a 13 mm 12-point box wrench over the
cable retainer at the intermediate bracket as shown
to collapse the retainer fingers (Fig. 105).
(8) Pull the cable out of the intermediate bracket.
(9) Lower the vehicle.
(10) Remove the left front door sill molding.
(11) Remove the left front kick panel.
(12) Pull the parking brake cable strand forward
and disconnect the end button from the lever (pedal)
assembly mechanism reel (Fig. 106).
(13) Slide the cable out of the lever bracket.
(14) Lift back the carpet and pull the cable seal
loose from the floor pan (Fig. 102).
(15) Pull the front parking brake cable assembly
out of the vehicle through the hole in the floor pan.
REMOVAL - EXPORT
(Refer to 5 - BRAKES - BASE/PARKING BRAKE/
LEVER - REMOVAL)
INSTALLATION
INSTALLATION
(1) Pass front parking brake cable assembly
through hole in floor pan from the inside of the vehi-
cle.
(2) Pass cable strand button through the hole in
the lever (pedal) assembly bracket.
(3) Install cable retainer onto the park brake cable
and then install cable retainer into pedal assembly
bracket.
Fig. 103 Parking Brake Cable Equalizer
1 - INTERMEDIATE BRACKET
2 - EQUALIZER
3 - LEFT REAR CABLE
4 - RIGHT REAR CABLE
5 - FRONT CABLE
Fig. 104 Front Parking Brake Cable Routing
1 - SCREW
2 - ROUTING BRACKET
3 - SCREW
4 - INTERMEDIATE BRACKET
5 - FRONT CABLE
6 - ROUTING BRACKET
Fig. 105 Cable Removal Using Wrench
1 - CABLE RETAINER
2 - 12-POINT BOX WRENCH
RSBRAKES - BASE5-67
CABLE - PARKING BRAKE FRONT (Continued)

(4) Install the end of the park brake cable into the
retainer previously installed into the park brake
pedal bracket.
(5) Install cable strand button into the clevis on
the park brake pedal mechanism.
(6) Install the front park brake cable floor pan seal
into hole in floor pan. Seal is to be installed so the
flange on the seal is flush with the floor pan (Fig.
102). Fold carpeting back down on floor.
(7) Raise vehicle.
(8) Insert brake cable and housing into body out-
rigger bracket making certain that housing retainer
fingers lock the housing firmly into place (Fig. 101).
(9) Manually reset the automatic self-adjusting
mechanism tension of the parking brake lever (pedal)
assembly. (Refer to 5 - BRAKES - STANDARD PRO-
CEDURE).
(10) Assemble the park brake cables onto the park
brake cable equalizer (Fig. 100).
(11) Lower vehicle and apply the park brake pedal
1 time. This will seat the parking brake cables.
INSTALLATION - FOLD-IN-FLOOR SEATING
(1) Pass most of the front parking brake cable
assembly down through hole in the floor pan from
inside the vehicle.
(2) Pass the lever-end cable strand button through
the hole in the lever (pedal) assembly bracket.
(3) Install the end of the cable housing into the
retainer installed into the park brake pedal bracket.(4) Install cable strand button into the reel on the
parking brake lever mechanism (Fig. 106).
(5) Install the front parking brake cable floor pan
seal into the hole in the floor pan. The seal flange
should be flush with the floor pan (Fig. 102).
(6) Reposition the carpeting back down on the
floor.
(7) Install the left front kick panel.
(8) Install the left front door sill molding.
(9) Raise and support the vehicle.
(10) Pass the end of the cable through the hole in
the end of the intermediate bracket (Fig. 104). Press
the cable housing retainer through the hole until the
fingers on the retainer lock it into place.
(11) Attach the front cable to the routing clips fas-
tened to the underbody of the vehicle (Fig. 104).
(12) Clamp an appropriate pair of locking pliers on
the front cable strand approximately 25 mm (1 inch)
forward of the button (Fig. 107).
(13) Pull straight back on the front cable button
(and pliers) and properly attach the equalizer to all
three parking brake cables (Fig. 103).
(14) Remove the locking pliers from the front park-
ing brake cable and allow the automatic self-adjust-
ing mechanism in the lever to take up any slack.
(15) Lower the vehicle.
(16) Apply and release park brake pedal 1 time.
This will seat the parking brake cables.
INSTALLATION - EXPORT
(Refer to 5 - BRAKES - BASE/PARKING BRAKE/
LEVER - INSTALLATION)
Fig. 106 Parking Brake Lever Assembly
1 - WIRING CONNECTOR
2 - MECHANISM REEL
3 - FRONT CABLE STRAND
4 - AUTO-ADJUST LOCKOUT PIN
5 - INDICATOR LAMP SWITCH
Fig. 107 Location To Grasp Cable At
5 - 68 BRAKES - BASERS
CABLE - PARKING BRAKE FRONT (Continued)

CABLE - PARKING BRAKE
INTERMEDIATE
REMOVAL
(1) Raise and support the vehicle. (Refer to
LUBRICATION & MAINTENANCE/HOISTING -
STANDARD PROCEDURE).
(2) Manually lock out the automatic self-adjusting
mechanism tension of the parking brake lever (pedal)
assembly. (Refer to 5 - BRAKES - STANDARD PRO-
CEDURE). Once the cable is released from the equal-
izer, do not remove the locking pliers until
reinstallation of the cable is complete.
(3) Remove the intermediate parking brake cable
from the parking brake cable equalizer (Fig. 108).
(4) Remove the locking nut securing the interme-
diate cable housing to the side bracket on the frame
rail (Fig. 108).
(5) Remove the intermediate parking brake cable
from the cable connector attaching it to the right
rear parking brake cable (Fig. 109). Remove the lock-
ing nut securing the intermediate cable housing to
the side bracket on the frame rail (Fig. 109).
(6) If the vehicle is a short-wheel-base model, it
will be necessary to loosen and lower the fuel tank
far enough to remove the intermediate parking brake
cable. (Refer to 14 - FUEL SYSTEM/FUEL DELIV-
ERY/FUEL TANK - REMOVAL).
(7) Remove the intermediate parking brake cable
from the side brackets and vehicle.
INSTALLATION
(1) Install the ends of the park brake cables
through the frame rails and into the side brackets.
(2) Install the locking nuts at each end of the cable
and securely tighten (Fig. 108) (Fig. 109).
(3) If the vehicle is a short-wheel-base model, it
will be necessary to reinstall the fuel tank to its nor-
mal mounting position. (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/FUEL TANK -
INSTALLATION).
(4) Install the intermediate parking brake cable on
the cable connector at the right rear parking brake
cable (Fig. 109).
(5) Install the intermediate park brake cable on
the cable equalizer (Fig. 108).
(6) Remove the locking pliers from the front park
brake cable. This will activate the automatic adjuster
and correctly adjust the parking brake cables.
(7) Install and position the foam collar on the
parking brake cable to prevent it from rattling
against the vehicle's floor.
(8) Lower the vehicle and apply the park brake
pedal 1 time, this will seat the park brake cables.
Fig. 108 Parking Brake Cable Attachment To
Equalizer
1 - EQUALIZER
2 - LEFT REAR PARKING BRAKE CABLE
3 - LOCKING NUT
4 - INTERMEDIATE PARKING BRAKE CABLE
5 - FRONT PARKING BRAKE CABLE
Fig. 109 Intermediate Cable Attachment To Right
1 - RIGHT REAR PARKING BRAKE CABLE
2 - LOCKING NUT
3 - INTERMEDIATE PARKING BRAKE CABLE
RSBRAKES - BASE5-69