tow LAND ROVER FRELANDER 2 2006 Repair Manual

Publi s hed: 11-May-2011
General Information - Standard Workshop Practices
Des cript ion and Operat ion
Vehicle in Workshop
W hen working on a vehicl e in the workshop al ways make sure t hat :
W here practi cable, t he parking brake is appli ed and t he wheel s are securely chocked to prevent t he vehi cl e movingforwards or backwards .W henever pos si ble, t he ignit ion key i s removed before any work is carried out on t he vehi cle.If the engine i s t o be run, t here i s adequat e vent il ati on, or an extract ion hos e i s us ed to remove exhaus t fumes.There i s adequat e room to rais e the vehicle and remove t he wheel s , if neces s ary.Fender covers are al ways ins tal led i f any work i s to be carri ed out in t he engine compart ment.W here practi cable, t he batt ery i s dis connected if worki ng on the engi ne, underneath t he vehicle, or if t he vehi cl e i srai sed.
• CAUTIO NS:
Prior to dis connect ing the bat tery, refer to the El ect ri cal Secti on of this manual - Bat tery dis connect ion/connect ion.For addit ional informat ion, refer t o: Specificati ons (414-01 Bat t ery, Mount ing and Cables , Speci ficat ions).
W hen el ect ri c arc wel ding on a vehi cl e, al ways dis connect t he generator wi ri ng to prevent t he pos si bili ty of a s urgeof current caus i ng damage to the i nternal component s of the generat or.
If us i ng welding equipment on t he vehicle, a s uit abl e fire exti nguis her is readily avail able.
Battery - General
• CAUTIO NS:
Prior to carrying out any procedures which i nvol ve dis connect ing/ or connecti ng the bat tery, refer t o t he ElectricalSect ion of t his manual - Batt ery di sconnect ion/connect ion.For addit ional informat ion, refer t o: Specificati ons (414-01 Bat t ery, Mount ing and Cables , Speci ficat ions).
A di s charged bat tery condit ion may have been caus ed by an electrical short ci rcuit . If t his condit ion exis t s there wil lbe an apparentl y li ve circuit on the vehicle even when al l normal circuit s are s wit ched off. This can cause arcing when t hejumper cables are connect ed.
W hi le it i s not recommended that the vehicl e is jump s t art ed, i t is recognized t hat thi s may occas ionall y be t he onl ypracti cal way t o mobi lize a vehi cl e. Prior t o at tempt ing a jump s t art , reference must be made to the El ect ri cal Secti on oft hi s manual - Jump St art ing.
Followi ng jump s tart ing of a dis abl ed vehi cle, the di s charged bat tery mus t be checked for s erviceabili ty and recharged offt he vehi cl e as s oon as poss ibl e t o avoi d permanent damage.
Do not rel y on t he generator t o res t ore a di s charged bat tery. For a generat or t o recharge a batt ery, it woul d take i n exces sof eight hours cont inuous dri vi ng wi th no addi ti onal loads placed on t he batt ery.
Always make s ure that t he jumper cabl es are adequate for the tas k.Always make s ure that t he s lave batt ery i s of the same vol tage as t he vehicle bat tery. The bat teries mus t beconnected i n paral lel.Always make s ure that s wit chabl e electric circui ts are s wi tched off before connecti ng jumper cabl es. This reducest he ri sk of arci ng occurring when the final connecti on is made.
Towing the Vehicle
W ARNING: W hen t owing i s neces sary, reference mus t be made to the Jacki ng, Lift ing and Towing Secti on of thi sManual .
W hen t he vehicle i s being t owed dock the remote cont rol and s wit ch on the ignit ion. (s t eering l ock releas ed and warni ngli ght s i ll uminated). Onl y t hen wil l the s t eering, turn s ignal lamps , horn and s t op lamps be operat ional. Fail ure t o followt hes e i nst ructi ons may res ult in pers onal injury. It mus t be noted that wit h t he engine not running, t he power s t eering andbrake boost er wil l be inoperat ive t herefore, great er effort wil l be needed t o s t eer t he vehicle and apply the brakes .
General Installation Instructions
Component removal
W henever pos si ble, clean component s and the surroundi ng area before removal .
Blank off openings expos ed by component removal .Followi ng dis connecti on, s eal fuel, oil or hydrauli c li nes i mmediat ely us ing sui table bl anki ng plugs or caps .Seal open ends of expos ed oil ways us i ng sui table tapered hardwood pl ugs or cons pi cuous pl as t ic pl ugs .Immediat el y a component i s removed, place it i n a sui table contai ner; us e a s eparate cont ai ner for each componentand it s as s ociat ed part s .

t ank must be ins tall ed.
Oil seals
Never us e a seal which has been improperly st ored or handled.
Take great care when removi ng old seals that t he seal ing s urfaces and s eal hous ing are not damaged.Careful ly exami ne seal before ins tal li ng to make s ure t hat it is cl ean and undamaged.Make s ure t hat the s urface on which t he s eal i s t o run and als o t he s eal housi ng is cl ean and free from burrs ors cratches. Renew t he component i f the s eali ng surface cannot be rest ored.Speci al t ools and prot ect ion sl eeves are provided for ins tall ing t he majori ty of s eals and mus t be us ed whens pecified.Many s eal s are now coat ed wi th a prot ect ive wax and DO NOT need t o be l ubricated prior t o ins t al li ng. Al wayscheck t he rel evant repair procedure which wil l s tat e if a seal mus t be ins t al led dry. Never t ouch t hes e seals wit hoil y hands as the oi l will contami nat e t he prot ect ive coati ng and affect t he s eal ing properti es of the s eal; al so,make s ure that ins tal li ng tools and protecti on s leeves are free from oil and greas e. Seal s which mus t be l ubricat edpri or to i nst all ing s hould have t he recommended lubri cant appli ed to the areas specified i n t he repair procedure.Make s ure t hat a s eal i s ins t al led t he correct way round. For exampl e, the l ip of t he s eal must face towards thelubricant whi ch it i s s eal ing.W hen i nst all ing an oi l seal, make sure t hat i t is pos it ioned s quare t o s haft and housi ng. W here t he s eal i s t o beins t al led t o a hous ing prior t o ins t al li ng over a shaft , t ake care not to al low the wei ght of an uns upported s haft t ores t on t he s eal .
Always us e t he recommended s pecial t ool and prot ecti on sl eeve to ins tall an oi l seal. If no t ool i s s peci fied, us e as uit abl e mandrel approximat el y 0.4 mm (0.015 in) s mall er than t he outs ide di ameter of the seal. Us e adhes ivet ape on the s haft t o protect the s eali ng li p of the seal.
Pres s or dri ft t he s eal i n t o t he dept h of it s hous ing i f the hous ing i s s houldered or fl us h wit h the face of thehous i ng where no shoulder is provi ded. Make s ure that t he s eal i s not ti lt ed in the hous ing when i t is i nst all ed.
Supplementary Restraint System (SRS) Precautions
W ARNING: Do not ins tal l rear facing chil d s eat s i n the front pas s enger s eat .
The SRS cont ains component s which are potent iall y hazardous t o s ervi ce personnel if not handl ed correctl y. The foll owingguideli nes and precaut ions are intended t o alert pers onnel to pot enti al s ources of danger and emphasi s e the import ance ofensuring t he int egrit y of t he SRS components ins tal led t o t he vehi cl e.
W ARNING: The foll owing precauti ons MUST be adhered t o when worki ng on t he SRS s ys t em:
T he correct procedures must always be used w hen working on SRS components.Persons w orking on the SRS system must be fully trained and have been issued w ith the safety guidelines.T he airbag modules contain extremely flammable and hazardous compounds. Contact with water, acids orheavy metals may produce harmful or explosive results. Do not dismantle, incinerate or bring into contactwith electricity before the unit has been deployed.Alw ays replace a seat belt assembly that has withstood the strain of a severe vehicle impact or if the webbing

Invert the compres s or and gravi ty drain the oi l into a calibrated meas uri ng cyl inder. Rotat e t he compres sor clut ch tomake s ure the compres s or is complet el y drai ned.Note the quanti ty of oi l drained (Y cm³).Calculate the quanti ty of oi l to be drained from t he new compres sor us ing t he fol lowi ng formula:X cm³ — (Y cm³ +20 cm³) = Q cm³Remove the drain pl ug from the new compres s or and drain Q cm3 of oi l. ins t al l and tight en t he compres sor drai nplug.
Vehicle Weights
Itemkglb
Maximum Gros s Vehicle W eight (GVW ) - Al l model s (1)25055511Approximate unladen w eight (2):
3.2 Petrol18254015
2.2 Diesel18204004Maximum weight of unbraked trailer:
On-road7501650
Off-road7501650Maximum towable weight (mass) - T railers with overrun brakes:
On-road20004400
Off-road20004400Gross train weight - T railers with overrun brakes (3):
On-road45059911
Off-road45059911Nose w eight:
On-road150330
Off-road150330Maximum front axl e l oad - All models (4)13102882
Maximum rear axle load - All models (4)13602992
Maximum roof rack l oad - All models (5)75165(1) T he maximum permissible weight of the vehicle including passengers and load.
(2) T his figure includes the toolkit, all fluids to the correct levels and spare w heel but excludes the driver andpassengers.
(3) T he maximum permissible weight of the vehicle and braked trailer and their respective loads.
(4) T he front and rear maximum loads cannot be reached simultaneously as this will exceed the GVW limit. Whencalculating rear axle loading, remember that the trailer nose w eight, the load in the vehicle' s luggage area, w eighton the roof rack, and the weight of rear seat passengers must all be added together.
(5) T his figure includes the weight of the roofrack.
Vehicle Dimensions
ItemmminLengt h - excluding l icens e pl ate pl int h - All models4500177.2
Width - All models:
Mirrors extended218085.83Mirrors folded200578.95
Maximum height - including roof rail s - Al l model s182071.65
W heelbas e - Al l model s2660104.7T rack:
Front w ith 16" wheels161163.43
Front w ith 17"/18"/19" wheels160163.03Rear with 16" wheels162463.94
Rear with 17"/18"19" wheels161463.54
Vehicle ride height (1):Front490.7±1219.32±0.47
Rear504.6±1219.87±0.47
Underbody running cl earance t o exhaus t - Mi nimum - Kerb wei ght2299.0Front axle t o underbody clearance2168.5
Rear axl e t o different ial cas i ng cl earance26710.5
Suspension travel from kerb - ROW (unladen):2278.9Front (bump/rebound)105/804.13/3.15
Rear (bump/rebound)130/905.12/3.54
T otal articulation33513.2Suspension travel from kerb - NAS (unladen):
Front (bump/rebound)102/764/3
Rear (bump/rebound)127/895/3.5T otal articulation33013.2
W adi ng dept h50019.7
Depart ure angle - Towbar NOT ins tall ed34°Depart ure angle - Fi xed hei ght towbar - NOT NAS vehicles19°
Depart ure angle - Detachabl e towbar ins t al led - NOT NAS vehicle18°
Depart ure angle - Towbar i ns t alled - NAS vehi cl es19°Approach angl e31°
Breakover angle157°
Maximum gradient for conti nuous operat ion30°Maximum gradient for drive t hrough operat ion (2)45°

Publi s hed: 11-May-2011
Jacking and Lifting - Vehicle Recovery
Des cript ion and Operat ion
Towing Points
CAUTION: The s ingle towi ng poi nts at t he front and rear of t he vehi cl e are des igned for vehicl e recovery purpos esonly and mus t NOT be used to t ow a trail er or caravan.
The front towi ng eye is acces s ibl e aft er releas ing t he 2 t oggle fast eners s ecuring the t owing eye acces s panel andremovi ng the panel.
CAUTION: Ens ure t hat during t owing, the towi ng att achment does not contact t he bumper.
The rear t owing eye i s acces si ble after rel eas i ng the 2 toggle fas teners securi ng the towing eye access panel and removingt he panel.
CAUTION: This t owing eye s hould onl y be us ed for t owing another vehi cl e or for recovery purpos es .
Towing the vehicle on four wheels
• W ARNINGS:
Ens ure t hat the remote cont rol remai ns docked whil s t the vehicle is being towed. Removi ng the remot e cont rol wi llengage t he s t eering l ock, which wi ll prevent the vehicle from s t eering correct ly.
If the engine cannot be run whi ls t t he vehi cl e i s bei ng t owed, t here wi ll be no power as si s tance for t he s teeri ng orbrakes. Thi s wil l res ult in greater effort bei ng required to st eer or sl ow t he vehi cl e, and greatl y increas ed s toppingdis t ances.
• CAUTIO NS:
The vehicle s hould onl y be t owed wit h four wheels on the ground. Towing wi th two wheel s on t he ground wi ll res ultin serious damage t o t he trans mi s si on.
The vehicle s hould onl y be t owed for a maxi mum of 80 km (50 mil es), at a maximum s peed of 80 km/h (50 mph).Towing for a great er di st ance, or at a higher s peed may res ult i n s eri ous damage t o t he t rans mis s ion.
• NOTE: The recommended recovery met hod is to rais e al l four wheel s.
Towing procedure
1. The vehi cl e s houl d be parked on firm level ground, wi th t he park brake on, and the gear s el ect or in P if an aut omati cgearbox is fit t ed.
2. Secure the towing at t achment from the recovery vehicle to the front t owing eye.
CAUTION: Leavi ng the ignit ion s wi tched on for extended peri ods wil l caus e the bat tery t o drai n.
3. Dock the remote cont rol, and s wi tch on t he igni ti on.
4. Appl y t he foot brake, and s el ect neutral.
5. W i th the foot brake s t ill appli ed, releas e the park brake.

6. The vehi cl e can now be t owed a maxi mum of 80 km (50 mil es) at a maxi mum speed of 80 km/h (50 mph).
7. Upon arrival at t he des ti nat ion, ensure wherever pos s ibl e that t he vehi cl e i s par
ked on firm l evel ground.
8. Appl y t he park brake, and place t he s el ect or lever into the P pos i ti on.
9. Swit ch off t he ignit ion, and remove t he remote control. W ARNING: Use ext reme caut ion when det aching towing equi pment . Vehi cle movement is po
s s ible which can res ult i n
s erious i njuri es.
10. Remove the t owing at tachment from t he t owing eye.
Lashing Points
• W ARNINGS: Us e t he las hing poi nt s at t he front and rear of the vehicle, DO NOT s ecure las hing
hooks or res traint s to any other
part of t he vehi cl e. The front and rear l as hing poi nt s mus t only be used for s ecuri ng t he vehi cl e duri ng
trans port ati on.The grahics s how t he front and rear las hing point s .
Transporting by trailer CAUTION: Us e t he las hing point s at t he front and rear of the vehicle, DO NOT s ecure
las hing hooks or res traint s to
any other part of t he vehi cl e.
Posi ti on t he vehi cl e, apply the parki ng brake and s elect 'N' - Neutral. The recommen ded met hod for recovery/t rans portat ion
of the vehicle, i s on a t rans port er or t rai ler desi gned for t hat purpos e.

ItemPart NumberDescription
A-Front brake cal iper - i6 gas oli ne vehi cl eB-Front brake cal iper - TD4 dies el vehicle
The cal iper as sembl y compris es a fixed carrier and s li ding caliper. The fi xed carrier i s mounted t o s t raddle t he brake di scand is at t ached t o t he wheel knuckl e wit h 2 bol ts . The fixed carri er provides the locat ion for 2 brake pads t hat aremounted on ei ther s ide of t he brake di sc, and is formed wit h guide channel s t hat al low t he brake pads t o s li de toward t hedis c s urface.
• NOTE: The 2 fixed carrier ret aining bol ts are pre-appl ied wi th a t hread locking adhesi ve and mus t not be re-us ed duringmaint enance. New fixed carri er ret ai ning bolt s mus t be us ed and t he ori gi nal bolt s di scarded.
The s li di ng cal iper is mount ed over the fixed carrier and ret ains t he 2 brake pads wi thi n the cal iper as s embly. The s li di ngcal iper is secured t o t he fixed carri er wit h 2 bus hed bol ts , and i s formed wi th a hydraul ic chamber cont ai ning a 60 mm(2.36 in) di ameter pis t on and annular s eal.
The s li di ng cal iper is connect ed via a fl exi ble hos e t o t he brake s yst em hydrauli c circui t, and als o i ncorporates a bleeds crew for maint enance purposes .
The 2 bus hed bol ts are machined wi th a s mooth surface and are protect ed from di rt and moi st ure ingres s wi th a col laps iblerubber boot . The bushed bolt s all ow t he s li di ng caliper li mi ted l ateral movement along t he fi xed carri er.
A hous ing s pri ng is locat ed on t he outer s ide of t he brake dis c, and is connect ed wit h formed hooks between t he fixedcarri er and sl idi ng cal iper. During operat ion of t he brake, t he s pri ng is tens ioned as the sl iding cal iper moves toward thebrake dis c. The s pring as s is t s to move t he sl idi ng cal iper away from t he brake di sc as the brake is released.
An anti -s queal s him i s ins tal led on t he outs i de edge of each brake pad and reduces Nois e, Vibrat ion and Hars hnes s (NVH)from the brake component s duri ng operati on.
The brake pads are not i nst all ed wit h pad wear s ens ors .
BRAKE DUST SHIELD
A formed brake dust s hiel d is locat ed between t he wheel knuckle and brake di s c, and i s s ecured to the knuckl e wit h 3s crews .
The brake dus t shi eld i s handed t o t he rel evant s ide of t he vehicle and protects t he brake component s from cros s axl es tone t hrows . The brake dus t shi el d als o prevent s debris and brake dust from s preading t o other part s of t he vehi cl e.
PRINCIPLES OF OPERATION
Brake Application
As t he brake pedal i s applied, ini ti al hydrauli c pres s ure i s fel t in the s l iding cali per chamber caus ing t he pis t on to ext endt oward t he brake dis c. The moving pis t on cont act s t he inner brake pad, forci ng the pad al ong the fixed carrier guidechannels and i nto cont act wi th the i nner s ide of t he brake di sc.
As t he pis ton ext ends from t he cal iper chamber, it pas ses t hrough an i nternal annul ar seal located wit hi n t he cal iper

chamber. The movement of t he pis t on dis torts t he s hape of the s eal and cons equent ly, the s eal appl ies pres s ure on thepis t on out er s urface.
The s li di ng cal iper now react s and commences t o s li de along t he 2 bus hed bol ts , i n the oppos it e direct ion t o t he extendingpis t on. The s li ding cali per contacts t he outer brake pad, forcing t he pad along t he fi xed carri er gui de channels and i nt ocont act wit h the out er si de of the brake dis c. The hous ing s pri ng t hat i s att ached bet ween the fi xed carrier and s li dingcal iper is tens ioned as t he sl idi ng cal iper moves toward the brake dis c.
W i th bot h brake pads now in full cont act wit h the brake dis c and hydraulic pres sure act ing on the pi s ton, no furthermovement of t he pis t on and s li di ng cal iper is pos s ible. The force creat ed by the pi ston and cali per acti ng agai nst the brakepads increas es rapidly, t rapping t he brake di sc and sl owing t he vehi cl e.
Brake Release
As t he brake pedal i s rel eas ed, hydraul ic press ure in the cali per chamber coll apses and force i s no longer appl ied t o t hebrake pads. The brake pads are moved s li ght ly out wards by t he acti on of the rotat ing brake di s c, and t he caliper int ernalannul ar seal ret urns t o t he normal s hape. As t he s eal moves i t gri ps on the pi s ton out er s urface and wit hdraws t he pis t onint o t he chamber, suffi ci ent ly to provi de t he neces sary pad t o dis c clearance.
This acti on prevents t he pis t on from hol di ng t he inner brake pad agai nst t he dis c, and als o enables t he pis ton to protrudefurther from the cali per chamber to compens at e for brake pad wear.
W i th no pres s ure being appli ed t o the hydraul ic s yst em, t he hous i ng spring t ensi on is al s o rel ieved and the spring returnst o the normal pos i ti on. As t he housi ng s pri ng moves , t he att ached s l iding cali per i s moved away from the out er s i de of thedis c t o provide the neces s ary cl earance bet ween the out er brake pad and the brake dis c.

The brake dis c al so forms t he locati on for t he parking brake component s . The brake d is c i nt ernal diamet er is 185 mm (7.28
in) and i s machined wit h a smoot h s urface to form t he brake drum. An int egral backpl
ate and brake dust s hiel d is mount ed
t o the rear of the brake di s c. The backpl at e enclos es the brake dis c and als o provi d es the mount ing l ocat ion for t he 2
parking brake shoes and operat ing component s.
An apert ure i s formed i n t he dust s hiel d and backplat e t hat al lows t he parking brake cable to protrude t hrough to the i nner
s ide of t he brake dis c, and connect to t he parki ng brake expander uni t. A hol e machi ned i n t he brake dis c outer hub
provides acces s t o t he parking brake manual adjus ter.
For addit ional informat ion, refer t o: Parking Brake (206-05 Parki ng Brake and Act uat ion, Descripti on and Operat ion).
CALIPER ASSEMBLY Item
Part Number Description
A -Rear brake caliper - i 6 gasol ine vehicle
B -Rear brake caliper - TD4 di es el vehi cl e
The cal iper as sembl y compris es a fixed carrier and s li ding caliper. The fi xed carrie r i s mounted t o s t raddle t he brake di sc
and is at t ached t o t he wheel knuckl e wit h 2 bol ts . The fixed carri er provides the lo cat ion for 2 brake pads t hat are
mounted on ei ther s ide of t he brake di sc, and is formed wit h guide channel s t hat al l ow t he brake pads t o s li de toward t he
dis c s urface.
• NOTE: The 2 fixed carrier ret aining bol ts are pre-appl ied wi th a t hread locking ad hesi ve and mus t not be re-us ed during
maint enance. New fixed carri er ret ai ning bolt s mus t be us ed and t he ori gi nal bolt s d i scarded.
The s li di ng cal iper is mount ed over the fixed carrier and ret ains t he 2 brake pads w i thi n the cal iper as s embly. The s li di ng
cal iper is secured t o t he fixed carri er wit h 2 bus hed bol ts , and i s formed wi th a hy draul ic chamber cont ai ning a pi s ton and
annul ar seal.
The s li di ng cal iper is connect ed via a fl exi ble hos e t o t he brake s yst em hydrauli c c ircui t, and als o i ncorporates a bleed
s crew for maint enance purposes .
The 2 bus hed bol ts are machined wi th a s mooth surface and are protect ed from di rt an d moi st ure ingres s wi th a col laps ible
rubber boot . The bushed bolt s all ow t he s li di ng caliper li mi ted l ateral movement alo ng t he fi xed carri er.
An anti -s queal s him i s ins tal led on t he outs i de edge of each brake pad and reduces N ois e, Vibrat ion and Hars hnes s (NVH)
from the brake component s duri ng operati on.
An upper and lower brake pad ret aining spring are mounted bet ween the fixed carrier and s li di ng caliper. The retai ning
s prings are held i n pos it ion by t he 2 bus hed bol ts , and mai ntain pres sure on t he bra ke pads t o prevent radial movement of
t he pads away from t he brake dis c.
The brake pads are not i nst all ed wit h pad wear s ens ors .
BRAKE DUST SHIELD
A formed brake dust s hiel d and int egral parking brake backpl ate is l ocat ed bet ween t he wheel knuckl e and brake dis c, and
is secured t o t he knuckle wit h 4 s crews .

5-Brake shoe retai ni ng s pri ng
6-Brake shoe return s pri ng
7-Brake shoe mechanical adjust er8-Lower (l eadi ng) brake s hoe
9-Parki ng brake l ever cabl e
10-Parki ng brake cabl e equalizer11-Parki ng brake i nner cabl e
12-Equali zer fas t ener
13-Parki ng brake mi cros wit ch14-Parki ng brake l ever as sembl y
15-Parki ng brake outer cable
16-Brake dus t s hield
OVERVIEW
The parking brake is a manual ly actuat ed s ys t em t hat operat es brake s hoes located i n t he rear brake di scs . The ins idecent er of the rear brake dis c is manufact ured t o form the brake drum.
BRAKE SHOE ASSEMBLY
The brake s hoes are mount ed horizontal ly on an int egral brake dus t s hield and backplat e, and form an upper t rai li ng andlower l eading brake s hoe type s yst em. Retai ni ng pins pas s t hrough hol es in the dus t s hield and corres ponding hol es ineach brake s hoe bracket . Each pi n is secured t o t he brake s hoe wit h a ret ai ning cli p. The ret ai ning pins al low movement oft he brake s hoe toward the drum surface duri ng parking brake operat ion, but prevent si deways movement of the brake shoeaway from the dus t s hi eld.
An expander unit and manual adjust er are l ocat ed along t he hori zont al axis of t he dus t shi el d. The expander uni t isposi ti oned at the front of the dus t s hield and forms t he locati on for t he leading and t rai ling ends of t he brake s hoebracket s . The manual adjus t er i s mounted at t he rear of t he dust s hiel d and forms t he l ocati on and ful crum poi nt for theoppos it e ends of t he brake s hoe bracket s.
The manual adjus t er provides the means to adjust t he brake s hoe l ining t o drum clearance for maintenance purposes .Acces s t o t he manual adjus t er knurl ed wheel i s t hrough a formed hole in the front of the brake dis c. Adjust ment isrequired if t he brake s hoes or dis cs are renewed. A bedding-in procedure must al so be performed t o make s ure the drumbrakes operate sat is fact oril y.For addit ional informat ion, refer t o: Parking Brake Shoes Bedding-In (206-05 Parking Brake and Actuati on, GeneralProcedures).
The corres pondi ng ends of bot h t he upper and l ower brake shoe brackets are mai ntained i n contact wit h t he expander uni tand manual adjus t er by 2 ret urn springs . The return s pri ngs are l ocat ed bet ween t he ends of each upper and l ower brakes hoe and att ach to hol es formed in the brake shoe brackets . The ret urn springs pull t he brake s hoes away from t he drumwhen t he parking brake is released.
PARKING BRAKE LEVER
The parking brake lever is l ocat ed in t he floor cons ole bet ween the driver and pass enger s eats , and compri ses a toot hedquadrant , pawl and pres s-butt on rel eas e mechanis m. A si ngl e cabl e wi th a formed t hreaded rod-end connect s t he quadrantt o the equali zer unit , and is secured wit h eit her a locknut or a l ocking was her and nut.
The t hreaded rod all ows adjus tment s t o t he parking brake cable tens ion and parki ng brake lever travel t o be performed formaint enance purpos es.For addit ional informat ion, refer t o: Parking Brake Cabl e Adjus tment (206-05 Parki ng Brake and Actuat ion, GeneralProcedures).
The parking brake cable is routed from t he parking brake l ever equalizer, and al ong the chas si s t o t he rear parking brakeexpander uni t. The parki ng brake cabl e prot rudes t hrough t he brake dust s hiel d, and is formed wit h a nippl e that connectst o the expander unit . The oppos i te ends of each Left-Hand (LH) and Ri ght -Hand (RH) parking brake cabl e are formed wit h anipple that connect to the equali zer unit . The equal izer uni t makes sure t he LH and RH parki ng brake as s embl ies operat es imul taneous l y when the parking brake i s applied.
A micros wit ch is locat ed on t he base of the parki ng brake lever. The micros wit ch operates t he parking brake warni ngindicat or l amp l ocat ed in t he i ns t rument clus ter, when the parki ng brake i s appl ied.For addit ional informat ion, refer t o: Ins t rument Clus ter (413-01 Inst rument Cl us t er, Des cript ion and Operat ion).
PRINCIPLES OF OPERATION
As t he parking brake lever i s applied, t he toot hed quadrant rotat es and pul ls on the t hreaded rod and cable equali zer. Theequal izer pul ls t he 2 parki ng brake cables and operat es the 2 expander uni ts s i mult aneous ly. Movement of t he expanderunit caus es t he upper and l ower brake s hoes t o pivot agains t the manual adjus ter fulcrum, and t he brake s hoes cont actt he brake drum agai nst t he t ens i on of the 2 ret urn s pri ngs .
As t he parking brake lever quadrant rot ates , t he teet h on t he pawl engage wit h corresponding t eeth on the quadrant . Int he appl ied pos it ion, the pawl t eet h are held under spring t ensi on agai nst the quadrant teet h t o prevent the l ever fromdis engagi ng.
W i th the parki ng brake appli ed and the i gnit ion i n power mode 6 (ignit ion), t he mi cros wit ch connect s a ground to theins t rument clus ter and il lumi nat es t he parking brake warning i ndi cat or lamp.For addit ional informat ion, refer t o: Ins t rument Clus ter (413-01 Inst rument Cl us t er, Des cript ion and Operat ion).
W hen t he parking brake lever pres s-butt on is pres sed and t he l ever moved t o rel eas e t he parki ng brake, t he pawl teet hare rais ed clear from the quadrant t eet h. As the parki ng brake l ever i s lowered, t he parking brake cable cl oses t heexpander uni t and the brake s hoes are immediatel y moved away from the brake drum by the 2 ret urn s pri ngs .

Publi s hed: 11-May-2011
Parking Brake and Actuation - Parking Brake Rear Cables
Removal and Inst all ati on
Removal
Remove t he coi n t ray.1.
Remove t he s towage compart ment .2.
Remove t he adjus ti ng nut and di sconnect t he front parking brakecabl e.3.
Releas e t he rear parking brake cables and remove t hecompens at or.4.
5. W ARNING: Do not work on or under a vehi cle s upported onl yby a jack. Al ways support t he vehi cl e on s afet y s tands .
Rais e and s upport t he vehi cl e.
5.
Remove both rear wheel s and t ires .
Refer t o: W heel and Ti re (204-04 W heel s and Tires, Removal andInst all at ion).
6.