wheel MERCEDES-BENZ SPRINTER 2006 Service Manual

(3) Remove the front wheels (Refer to 22 - TIRES/
WHEELS/WHEELS - REMOVAL).
(4) Remove the wear indicator cable and the wear
indicator (Fig. 9).
NOTE: Seal off the line ends and connection
threads in the brake calipers with plugs. Also check
brake hoses for signs of cracks.
(5) Remove the brake hose at the brake caliper
(Fig. 9).
(6) Remove the brake caliper guide bolt (Fig. 9).
(7) Remove the brake caliper (Fig. 9).
REMOVAL - FRONT (DRW)
(1) Unscrew the cap from the brake fluid reservoir.
(2) Raise and support the vehicle.
(3) Remove the front wheels (Refer to 22 - TIRES/
WHEELS/WHEELS - REMOVAL).
(4) Remove the wear indicator cable and the wear
indicator (Fig. 10).
NOTE: Seal off the line ends and connection
threads in the brake calipers with plugs. Also check
brake hoses for signs of cracks.
(5) Remove the brake hose at the brake caliper
(Fig. 10).
(6) Remove the brake caliper guide bolt (Fig. 10).
(7) Remove the brake caliper (Fig. 10).
REMOVAL - REAR (SRW)
(1) Unscrew the cap from the brake fluid reservoir.
(2) Raise and support the vehicle.
(3) Remove the rear wheels (Refer to 22 - TIRES/
WHEELS/WHEELS - INSTALLATION).
(4) Remove the wear indicator cable and the wear
indicator (Fig. 11).
NOTE: Seal off the line ends and connection
threads in the brake calipers with plugs. Also check
brake hoses for signs of cracks.
(5) Remove the brake hose at the brake caliper
(Fig. 11).
(6) Remove the brake caliper guide bolt (Fig. 11).
(7) Remove the brake caliper (Fig. 11).
Fig. 9 FRONT DISC BRAKE CALIPER
1 - WEAR INDICATOR CABLE
2 - WEAR INDICATOR
3 - BOLT
4 - BRAKE HOSE
5 - DISC BRAKE CALIPER/ADAPTER
6 - ADAPTER BOLTS
Fig. 10 DISC BRAKE CALIPER WITH DUAL REAR
WHEELS
1 - WEAR INDICATOR WIRE
2 - WEAR INDICATOR
3 - MOUNTING BOLT
4 - BRAKE HOSE
5 - DISC BRAKE CALIPER
6 - ADAPTOR BOLTS
5 - 12 BRAKES - BASEVA

REMOVAL - REAR (DRW)
(1) Unscrew the cap from the brake fluid reservoir.
(2) Raise and support the vehicle.
(3) Remove the rear wheels (Refer to 22 - TIRES/
WHEELS/WHEELS - INSTALLATION).
(4) Remove the wear indicator cable and the wear
indicator (Fig. 12).
NOTE: Seal off the line ends and connection
threads in the brake calipers with plugs. Also check
brake hoses for signs of cracks.
(5) Remove the brake hose at the brake caliper
(Fig. 12).
(6) Remove the brake caliper guide bolt (Fig. 12).
(7) Remove the brake caliper (Fig. 12).INSTALLATION
INSTALLATION - FRONT (SRW)
(1) Install the brake caliper to the brake caliper
adapter (Fig. 9). Tighten the guide pins to 25 N´m
(221 in. lbs.).
NOTE: Do not install the brake hose twisted and
ensure freedom of movement.
(2) Install the brake hose at the brake caliper (Fig.
9). Tighten the bolt to 14 N´m (124 in. lbs.).
(3) Install the wear indicator cable and the wear
indicator (Fig. 9). Tighten to 10 N´m (89 in. lbs.).
(4) Bleed the brake system.
(5) Check the brake system for any leaks.
(6) Install the front wheels.
(7) Lower the vehicle.
INSTALLATION - FRONT (DRW)
(1) Install the brake caliper to the brake caliper
adapter (Fig. 10). Tighten the guide pins to 25 N´m
(221 in. lbs.)(M8 bolt) or Tighten the guide pins to 30
N´m (265 in. lbs.)(M10 10.9 bolt).
NOTE: Do not install the brake hose twisted and
ensure freedom of movement.
(2) Install the brake hose at the brake caliper (Fig.
10). Tighten the bolt to 14 N´m (124 in. lbs.).
(3) Install the wear indicator cable and the wear
indicator (Fig. 10). Tighten to 10 N´m (89 in. lbs.).
(4) Bleed the brake system.
(5) Check the brake system for any leaks.
Fig. 11 REAR DISC BRAKE CALIPER
1 - BRAKE HOSE
2 - BANJO BOLT
3 - WEAR INDICATOR
4 - CALIPER ADAPTER BOLTS
5 - DISC BRAKE CALIPER
6 - WEAR INDICATOR
Fig. 12 REAR DISC BRAKE CALIPER WITH DUAL
REAR WHEELS
1 - ADAPTER BOLT
2 - WEAR INDICATOR MOUNTING BOLT
3 - WEAR INDICATOR
4 - BRAKE LINE
5 - CLAMP
6 - BRAKE HOSE
7 - BRAKE CALIPER
VABRAKES - BASE 5 - 13

(6) Install the front wheels.
(7) Lower the vehicle.
INSTALLATION - REAR (SRW)
(1) Install the brake caliper to brake caliper
adapter (Fig. 11). Tighten the guide bolt to 25 N´m
(221 in. lbs.) for M8 bolt or 30 N´m (266 in. lbs.) for
M10 bolt.
NOTE: Do not install the brake hose twisted and
ensure freedom of movement.
(2) Install the brake hose at the brake caliper (Fig.
11). Tighten the bolt to 14 N´m (124 in. lbs.).
(3) Install the wear indicator cable and the wear
indicator (Fig. 11). Tighten to 10 N´m (89 in. lbs.).
(4) Bleed the brake system.
(5) Check the brake system for any leaks.
(6) Install the rear wheels (Refer to 22 - TIRES/
WHEELS/WHEELS - INSTALLATION).
(7) Lower the vehicle.
INSTALLATION - REAR (DRW)
(1) Install the brake caliper to brake caliper
adapter (Fig. 12). Tighten the guide bolt to 25 N´m
(221 in. lbs.) for M8 bolt or 30 N´m (266 in. lbs.) for
M10 bolt.
NOTE: Do not install the brake hose twisted and
ensure freedom of movement.
(2) Install the brake hose at the brake caliper (Fig.
12). Tighten the bolt to 14 N´m (124 in. lbs.).
(3) Install the wear indicator cable and the wear
indicator (Fig. 12). Tighten to 10 N´m (89 in. lbs.).
(4) Bleed the brake system.
(5) Check the brake system for any leaks.
(6) Install the rear wheels (Refer to 22 - TIRES/
WHEELS/WHEELS - INSTALLATION).
(7) Lower the vehicle.
DISC BRAKE CALIPER
ADAPTER
REMOVAL
REMOVAL - FRONT
(1) Unscrew the cap from the brake fluid reservoir.
(2) Raise and support the vehicle.
(3) Remove the front wheels (Refer to 22 - TIRES/
WHEELS/WHEELS - REMOVAL).
(4) Remove the disc brake caliper from the caliper
adapter (Refer to 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/DISC BRAKE CALIPERS - REMOVAL).(5) Remove the disc brake pads (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/BRAKE
PADS/SHOES - REMOVAL).
(6) Remove the disc brake caliper adapter.
REMOVAL - REAR
(1) Unscrew the cap from the brake fluid reservoir.
(2) Raise and support the vehicle.
(3) Remove the rear wheels (Refer to 22 - TIRES/
WHEELS/WHEELS - INSTALLATION).
(4) Remove the disc brake caliper.
(5) Remove the disc brake pads.
(6) Remove the disc brake caliper adapter.
INSTALLATION
INSTALLATION - FRONT
(1) Install the brake caliper adapter to the steering
knuckle. Tighten to 170 N´m (125 ft. lbs.).
(2) Install the disc brake shoes (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/BRAKE
PADS/SHOES - INSTALLATION).
NOTE: Do not install the brake hose twisted and
ensure freedom of movement.
(3) Install the disc brake caliper. Tighten the bolt
to 14 N´m (124 in. lbs.) (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/DISC BRAKE CALIPERS
- INSTALLATION).
(4) Install the front wheels (Refer to 22 - TIRES/
WHEELS/WHEELS - INSTALLATION).
(5) Lower the vehicle.
INSTALLATION - REAR
(1) Install the brake caliper adapter to the axle
mount. Tighten to 90 N´m (66 ft. lbs.) for M12X1.5
bolt or 170 N´m (125 ft. lbs.) for M14X1.5 bolt.
(2) Install the disc brake pads (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/BRAKE
PADS/SHOES - INSTALLATION).
NOTE: Do not install the brake hose twisted and
ensure freedom of movement.
(3) Install the disc brake caliper (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPERS - INSTALLATION).
(4) Install the rear wheels (Refer to 22 - TIRES/
WHEELS/WHEELS - INSTALLATION).
(5) Lower the vehicle.
5 - 14 BRAKES - BASEVA

edge of the diaphragm is secured to the housing. The
booster push rod, which connects the booster to the
brake pedal and master cylinder, is attached to the
center of the diaphragm. A check valve is used in the
booster outlet connected to the engine intake mani-
fold. Power assist is generated by utilizing a combi-
nation of vacuum and atmospheric pressure to boost
brake assist.
REMOVAL
(1) Using a suction gun remove as much brake
fluid from the reservoir as possible.
(2) Disconnect the brake level switch electrical
connector.
(3) Remove the brake lines from the master cylin-
derSeal off the ends and bore holes with plugs.
(4) Remove the master cylinder from the booster.
(5) Remove the booster vacuum hose and check
valve (Fig. 23).
(6) Remove the pedal push rod clip (Fig. 23).
(7) Remove the booster mounting nuts (Fig. 23).
(8) Remove the booster from the vehicle.
INSTALLATION
(1) Install the brake booster to the vehicle.
(2) Install the booster mounting nuts (Fig. 23).
Tighten to 25 N´m (221 in.lbs.).
(3) Install the push rod pin & clip (Fig. 23).
(4) Install the brake booster vacuum line and
check valve (Fig. 23).
(5) Install the master cylinder to the brake
booster. Tighten to 28 N´m (248 in.lbs.).
(6) Install the brake lines to the master cylinder.
Tighten to 14 N´m (124 in.lbs.).
(7) Install the brake level switch electrical connec-
tor.(8) Bleed the base brake system (Refer to 5 -
BRAKES - STANDARD PROCEDURE).
ROTORS
REMOVAL
REMOVAL - FRONT (SRW)
(1) Raise and support the vehicle.
(2) Remove the front wheels.
(3) Remove the front brake pads (Fig. 24).
(4) Remove the caliper adapter (Fig. 24).
(5) Install two lug studs to secure the disc brake
rotor when the locking bolt is removed.
(6) Remove the locking bolt for the disc brake rotor
(Fig. 24).
(7) Remove the two lug nuts.
(8) Remove the disc brake rotor (Fig. 24).
REMOVAL - REAR (SRW)
(1) Raise and support the vehicle.
(2) Remove the rear wheels.
(3) Remove the rear disc brake pads (Fig. 25).
(4) Remove the disc brake caliper adapter (Fig.
25).
(5) Apply the parking brake.
(6) Install two lug studs to secure the disc brake
rotor when the locking bolt is removed.
(7) Remove the locking bolt for the disc brake rotor
(Fig. 25).
(8) Remove the two lug nuts.
(9) Release the parking brake.
Fig. 23 POWER BRAKE BOOSTER
1 - VACUUM LINE & CHECK VALVE
2 - BRAKE BOOSTER
3 - GASKET
4 - MOUNTING NUTS (4)
5 - PUSH ROD PIN
6 - SECURING CLIP
Fig. 24 FRONT DISC BRAKE ROTOR
1 - CALIPER ADAPTER BOLT
2 - CALIPER ADAPTER
3 - GUIDE BOLT
4 - WEAR INDICATOR
5 - DISC BRAKE CALIPER
6 - DISC BRAKE PADS
7 - LOCKING BOLT
8 - DISC BRAKE ROTOR
5 - 20 BRAKES - BASEVA

(10) loosen the park brake adjuster to allow clear-
ance for the rotor removal (Fig. 25).
(11) Remove the rear disc brake rotor.
REMOVAL - FRONT (DRW)
(1) Raise and support the vehicle.
(2) Remove the front wheels.
(3) Remove the front brake pads (Fig. 26).
(4) Remove the caliper adapter (Fig. 26).
(5) Remove the wheel flange ring (Fig. 26).
(6) Install two lug studs to secure the disc brake
rotor when the locking bolt is removed.
(7) Remove the locking bolt for the disc brake rotor
(Fig. 26).
(8) Remove the two lug nuts.
(9) Remove the disc brake rotor (Fig. 26).
REMOVAL - REAR (DRW)
(1) Raise and support the vehicle.
(2) Remove the rear wheels.
(3) Remove the rear disc brake pads (Fig. 27).
(4) Remove the disc brake caliper adapter (Fig.
27).
(5) Apply the parking brake.
(6) Install two lug studs to secure the disc brake
rotor when the locking bolt is removed.
(7) Remove the wheel flange ring (Fig. 27).
(8) Remove the locking bolt for the disc brake rotor
(Fig. 27).
(9) Remove the two lug nuts.
(10) Release the parking brake.
(11) loosen the park brake adjuster to allow clear-
ance for the rotor removal (Fig. 27).
(12) Remove the rear disc brake rotor.
Fig. 25 REAR DISC BRAKE ROTOR
1-M8BOLT
2 - CALIPER ADAPTER
3 - DISC BRAKE ROTOR
4 - LOCKING BOLT
5 - DISC BRAKE PADS
6 - RATTLE SPRING
7 - DISC BRAKE CALIPER
8 - GUIDE BOLT
9 - COVER
10 - WEAR INDICATOR
Fig. 26 FRONT DISC BRAKE ROTOR WITH DUAL
REAR WHEELS
1 - ADAPTER BOLT
2 - ADAPTER
3 - GUIDE PIN/BOLT
4 - WEAR INDICATOR WIRE
5 - DISC BRAKE CALIPER
6 - DISC BRAKE PADS
7 - WHEEL FLANGE RING MOUNTING BOLT
8 - WHEEL FLANGE RING
9 - LOCKING BOLT
10 - DISC BRAKE ROTOR
VABRAKES - BASE 5 - 21

INSTALLATION
INSTALLATION - FRONT (SRW)
(1) Install the disc brake rotor to the hub and
install two lug studs to hold rotor in place.
(2) Install the locking bolt for the rotor (Fig. 24).
Tighten to 23 N´m (204 in. lbs.).
(3) Install the disc brake caliper adapter (Fig. 24).
Tighten to 170 N´m (125 ft. lbs.) (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPER ADAPTER - INSTALLATION).
(4) Install the brake pads (Refer to 5 - BRAKES/
HYDRAULIC/MECHANICAL/BRAKE PADS/SHOES
- INSTALLATION) (Fig. 24).
(5) Press and release the brake pedal several times
until pressure has built up.
(6) Check fluid in reservoir and correct if neces-
sary.
(7) Install the front wheels (Refer to 22 - TIRES/
WHEELS/WHEELS - INSTALLATION).
(8) Lower the vehicle.
INSTALLATION - REAR (SRW)
(1) Install the disc brake rotor to the hub and
install two lug studs to hold rotor in place (Fig. 25).
(2) Apply the parking brake.
(3) Install the locking bolt for the rotor (Fig. 25).
Tighten to 23 N´m (204 in. lbs.).
(4) Install the disc brake caliper adapter (Fig. 25).
Tighten to 90 N´m (66 ft. lbs.) (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALI-
PER ADAPTER - INSTALLATION).
(5) Install the brake pads (Refer to 5 - BRAKES/
HYDRAULIC/MECHANICAL/BRAKE PADS/SHOES
- INSTALLATION) (Fig. 25).
(6) Release the parking brake.
(7) Adjust the parking brake (Refer to 5 -
BRAKES/PARKING BRAKE/SHOES - ADJUST-
MENTS).
(8) Press and release the brake pedal several times
until pressure has built up.
(9) Check fluid in reservoir and correct if neces-
sary.
(10) Install the rear wheels.
(11) Lower the vehicle.
INSTALLATION - FRONT (DRW)
(1) Install the disc brake rotor to the hub and
install two lug studs to hold rotor in place.
(2) Install the locking bolt for the rotor (Fig. 26).
Tighten to 23 N´m (204 in. lbs.).
(3) Install the disc brake caliper adapter (Fig. 26).
Tighten to 170 N´m (125 ft. lbs.) (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPER ADAPTER - INSTALLATION).
(4) Install the wheel flange ring. Tighten to 180
N´m (133 ft. lbs.)
(5) Install the brake pads (Refer to 5 - BRAKES/
HYDRAULIC/MECHANICAL/BRAKE PADS/SHOES
- INSTALLATION) (Fig. 26).
(6) Press and release the brake pedal several times
until pressure has built up.
(7) Check fluid in reservoir and correct if neces-
sary.
(8) Install the front wheels (Refer to 22 - TIRES/
WHEELS/WHEELS - INSTALLATION).
(9) Lower the vehicle.
INSTALLATION - REAR (DRW)
(1) Install the disc brake rotor to the hub and
install two lug studs to hold rotor in place (Fig. 27).
(2) Apply the parking brake.
(3) Install the locking bolt for the rotor (Fig. 27).
Tighten to 23 N´m (204 in. lbs.).
(4) Install the disc brake caliper adapter (Fig. 27).
Tighten to 170 N´m (125 ft. lbs.) (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPER ADAPTER - INSTALLATION).
(5) Install the wheel flange ring (Fig. 27) Tighten
to 200 N´m (148 ft. lbs.).
(6) Install the brake pads (Refer to 5 - BRAKES/
HYDRAULIC/MECHANICAL/BRAKE PADS/SHOES
- INSTALLATION) (Fig. 27).
(7) Release the parking brake.
(8) Adjust the parking brake (Refer to 5 -
BRAKES/PARKING BRAKE/SHOES - ADJUST-
MENTS).
Fig. 27 REAR DISC BRAKE ROTOR WITH DUAL
REAR WHEELS
1 - ADAPTER BOLT
2 - ADAPTER
3 - GUIDE PIN/BOLT
4 - WEAR INDICATOR
5 - DISC BRAKE CALIPER
6 - RETAINING SPRING
7 - DISC BRAKE PADS
8 - WHEEL FLANGE RING MOUNITNG BOLT
9 - WHEEL FLANGE RING
10 - DISC BRAKE ROTOR
5 - 22 BRAKES - BASEVA

(9) Press and release the brake pedal several times
until pressure has built up.
(10) Check fluid in reservoir and correct if neces-
sary.
(11) Install the rear wheels.
(12) Lower the vehicle.
SUPPORT PLATE
REMOVAL - REAR
(1) Raise and support the vehicle.
(2) Remove the disc brake caliper adapter (Refer to
5 - BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPER ADAPTER - REMOVAL).
(3) Remove the disc brake rotor (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ROTORS -
REMOVAL).
(4) Remove the rear park brake shoes (Refer to 5 -
BRAKES/PARKING BRAKE/SHOES - REMOVAL).
(5) Remove the park brake cable from he support
plate.
(6) Remove the rear axle bearing (Refer to 3 - DIF-
FERENTIAL & DRIVELINE/REAR AXLE/AXLE
BEARINGS - REMOVAL).(7) Remove brake support plate.
INSTALLATION - REAR
(1) Press the brake support plate with the axle
bearing onto the axle shaft (Refer to 3 - DIFFEREN-
TIAL & DRIVELINE/REAR AXLE/AXLE BEARINGS
- INSTALLATION).
(2) Install the park brake cable to the support
plate.
(3) Install the rear park brake shoes (Refer to 5 -
BRAKES/PARKING BRAKE/SHOES - INSTALLA-
TION).
(4) Install the disc brake rotor (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ROTORS -
INSTALLATION).
(5) Install the disc brake caliper adapter (Refer to
5 - BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPER ADAPTER - INSTALLATION).
(6) Adjust the rear park brake shoes (Refer to 5 -
BRAKES/PARKING BRAKE/SHOES - ADJUST-
MENTS).
(7) Install the rear wheels (Refer to 22 - TIRES/
WHEELS/WHEELS - INSTALLATION).
PARKING BRAKE
SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Pressure Transformer Unit
For Brake Cables To
Frame Crossmember25 Ð 221
Hand Brake Lever To
Seat Frame25 Ð 221
VABRAKES - BASE 5 - 23

INSTALLATION - REAR
NOTE: Route the park brake cable free of tension
and the risk of chafing.
(1) Install the hand brake cable to the anchor
plate (Fig. 31).
(2) Install the park brake cable lock (Fig. 31).
(3) Install all connections on the hardware cable
(Fig. 31).
(4) Install the park brake cables to the shoe (Fig.
31).
(5) Install the park brake shoes.
(6) Install the rear wheels.
(7) Adjust the park brakes.
(8) Lower the vehicle.
ADJUSTMENTS
ADJUSTMENT - PARKING BRAKE CABLES
(1) Loosen the bolts of the mounting brackets (Fig.
33).
(2) Insert a drill bit or an allen wrench with a 6
mm diameter between the mounting bracket and
front lever (Fig. 33).
(3) Push the mounting bracket back until the front
brake cable is free of play and without tension (Fig.
33).
(4) Tighten the bolts to the mounting bracket
Tighten to 25 N´m (221 in. lbs.) (Fig. 33).
(5) Remove the 6 mm diameter drill bit or allen
wrench (Fig. 33).
(6) Tighten the hand brake lever one notch (Fig.
33).(7) Clamp the eccentric clockwise until the wheels/
disc brake rotors can still be turned with the force of
the hand (Fig. 34).
(8) Tighten the clamp bolt (Fig. 34).
(9) Release the hand brake lever.
(10) Check the wheel for free movement.
LEVER
REMOVAL
(1) Disconnect the front brake cable from the pul-
ley unit.
(2) Remove the front brake cable from the hand
brake lever (Fig. 29).
(3) Remove the circle cover (Fig. 35).
Fig. 32 FRONT PARK BRAKE CABLE
1 - RETAINING CLIP
2 - LOCKING PIN
3 - FRONT PARK BRAKE CABLE
4 - RETAINING CLIP
5 - PARK BRAKE CABLE ADJUSTER
Fig. 33 PARK BRAKE ADJUSTER
1 - LOOSEN MOUNTING BOLTS
2-6mmALLEN WRENCH
3 - MOUNTING BOLTS TIGHTENED
4 - FREEPLAY WITH NO TENSION
Fig. 34 PARK BRAKE ADJUSTMENT
1 - ECCENTRIC CLOCKWISE
2 - CLAMP SCREW TIGHTENED
5 - 26 BRAKES - BASEVA

(4) Remove the bolts on the hand brake lever (Fig.
35).
(5) Pull the cover off the hand brake lever (Fig.
35).
(6) Disconnect the hand brake check switch and
wiring harness from the hand brake lever (Fig. 35).
(7) Remove the hand brake lever (Fig. 35).
INSTALLATION
(1) Install the hand brake lever (Fig. 35).
(2) Reconnect the hand brake check switch and the
wiring harness to the hand brake lever (Fig. 35).
(3) Install the cover to the hand brake lever (Fig.
35).
(4) Install the bolts on the hand brake lever.
Tighten to 25 N´m (221 in. lbs.) (Fig. 35).
(5) Install the circle cover (Fig. 35).
(6) Install the front brake cable to the hand brake
lever.
(7) Connect the front brake cable to the pulley unit
(Fig. 35).
SHOES
REMOVAL
REMOVAL - (SRW)
(1) Raise and support the vehicle.
(2) Remove the rear wheels.
(3) Remove the disc brake rotor.(4) Disconnect the front park brake cable from the
pulley unit.Do not remove the rear park brake
cables.
(5) Remove the retracting springs using special
tool 9280 (Fig. 36).
(6) Remove the adjuster (Fig. 36).
(7) Remove the pressure springs using special tool
9281 (Fig. 36).
(8) Remove the rear park brake shoes (Fig. 36).
Pull the park brake shoes apart at the bottom
and remove them together with the adjuster.
REMOVAL - (DRW)
(1) Raise and support the vehicle.
(2) Remove the rear wheels.
(3) Remove the wheel flange ring.
(4) Remove the disc brake rotor.
(5) Disconnect the front park brake cable from the
pulley unit.Do not remove the rear park brake
cables.
(6) Remove the retracting springs (Fig. 37).
(7) Remove the adjuster (Fig. 37).
(8) Remove the pressure springs (Fig. 37). by
depressing with your fingers and twisting.
(9) Remove the rear park brake shoes (Fig. 37).
Pull the park brake shoes apart at the bottom
and remove them together with the adjuster.
Fig. 35 HAND BRAKE LEVER
1 - LOCKING PIN
2 - COVER
3 - HAND BRAKE LEVER
4 - HAND BRAKE CHECK SWITCH
5 - WIRING HARNESS
6 - BOLT
7 - HAND BRAKE CABLE
8 - BOLT
9 - RETAINING CLIP
10 - CIRCLE COVER
Fig. 36 PARK BRAKE SHOES
1 - PARK BRAKE SHOES
2 - PRESSURE SPRING
3 - RETRACTING SPRING (SHORT HOOK EYE)
4 - RETRACTING SPRING (LONG HOOK EYE)
5 - CABLE LOCK
6 - ADJUSTER
VABRAKES - BASE 5 - 27

CLEANING - REAR DRUM IN HAT BRAKE
Clean the individual brake components, including
the support plate exterior, with a water dampened
cloth or with brake cleaner. Do not use any other
cleaning agents. Remove light rust and scale from
the brake shoe contact pads on the support plate
with fine sandpaper.
INSTALLATION
INSTALLATION - (SRW)
NOTE: Preassemble the retracting spring with the
short hook eye from the inside together with the
adjuster wheel at the bottom. Fit the preassembled
park brake shoes on the brake carrier.
(1)Ensure that the cable lock moves easily
before installing shoes.Install the park brake
shoes.
(2) Install the lower retracting spring using special
tool 9280.
(3) Install the hold down springs using special tool
9281.
(4) Install the upper retracting spring using spe-
cial tool 9280.
(5) Install the adjuster.
(6) Install the front park brake cable to the pulley
unit.
(7) Install the disc brake rotor.
(8) Install the rear wheels.
(9) Adjust the parking brakes.(10) Lower the vehicle.
(11) Pump the brake pedal several times to check
the operation of the brakes before moving vehicle.
INSTALLATION - (DRW)
NOTE: Preassemble the retracting spring with the
short hook eye from the inside together with the
adjuster wheel at the bottom. Fit the preassembled
park brake shoes on the brake carrier.
(1)Ensure that the cable lock moves easily
before installing shoes.Install the park brake
shoes.
(2) Install the lower retracting spring.
(3) Install the pressure hold down springs by
depressing with your fingers and twisting to lock in
place.
(4) Install the upper retracting spring.
(5) Install the adjuster.
(6) Install the front park brake cable to the pulley
unit.
(7) Install the disc brake rotor.
(8) Install the rear wheel flange ring. Tighten to
200 N´m (148 ft. lbs.).
(9) Install the rear wheels.
(10) Adjust the parking brakes.
(11) Lower the vehicle.
(12) Pump the brake pedal several times to check
the operation of the brakes before moving vehicle.
ADJUSTMENTS
ADJUSTMENT
(1) Raise and support the vehicle.
(2) Remove the rear wheels.
(3) Turn the adjusting wheel through the hole of
the wheel lug bolt until it is no longer possible to
rotate the rear wheel (Fig. 38).
(4) Loosen the adjusting wheel 3-4 teeth divisions
(Fig. 38).
Fig. 37 PARK BRAKE SHOES WITH DUAL REAR
WHEELS
1 - HOLD DOWN PIN
2 - PRESSURE SPRING
3 - ADJUSTER
4 - UPPER RETRACTING SPRING
5 - LOWER RETRACTING SPRING
6 - CABLE LOCK
7 - LOCKING PIN
8 - BRAKE CABLE
9 - PARK BRAKE SHOE
5 - 28 BRAKES - BASEVA