AutoZone 1963 Chevrolet Nova 3.2L 1BL OHV 6cyl | Repair Guides | Brakes | Transmission Mounted Parking Brake | F-super Duty Model | AutoZone.com

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    1963 Chevrolet Nova 3.2L 1BL OHV 6cyl

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    See Details

    Ford Pick-ups and Broncos 1987-1996 Repair Guide

    F-Super Duty Model

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    To replace the brake shoes, or any other component, the unit must be disassembled.

    REMOVAL



    See Figures 1, 2, 3, 4, 5, 6 and 7



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    Fig. Fig. 1: F-Super Duty parking brake shoe return spring installation



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    Fig. Fig. 2: F-Super Duty parking brake unit removal



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    Fig. Fig. 3: F-Super Duty parking brake cables



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    Fig. Fig. 4: Removing the parking brake mainshaft locknut



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    Fig. Fig. 5: Removing the F-Super Duty parking brake output flange



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    Fig. Fig. 6: Removing the F-Super Duty parking brake splash shield



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    Fig. Fig. 7: Removing the F-Super Duty parking brake outer bearing cup

    1. Place the transmission in gear.
    2.  
    3. Fully release the parking brake pedal.
    4.  
    5. Raise and support the truck on jackstands.
    6.  
    7. Disconnect the speedometer cable.
    8.  
    9. Spray penetrating oil on the adjusting clevis, jam nut and threaded end of the cable.
    10.  
    11. Loosen the jam nut and remove the locking pin from the clevis pin.
    12.  
    13. Remove the clevis pin, clevis and jam nut from the cable.
    14.  
    15. Remove the cable from the bracket on the case.
    16.  
    17. Matchmark the driveshaft and disconnect it from the flange.
    18.  
    19. Remove the 6 hex-head bolts securing the parking brake unit to the transmission extension housing and lift off the unit.
    20.  

    The unit is filled with Ford Type H ATF.


    CAUTION
    Brake shoes may contain asbestos, which has been determined to be a cancer causing agent. Never clean the brake surfaces with compressed air! Avoid inhaling any dust from any brake surface! When cleaning brake surfaces, use a commercially available brake cleaning fluid.

    DISASSEMBLY



    Several special tools and a hydraulic press are necessary.

    1. Remove the unit from the truck.
    2.  
    3. Remove the 4 bolts securing the yoke flange and drum, and remove the flange and drum.
    4.  
    5. Remove the 75mm hex nut from the mainshaft, using tool T88T-2598-G, or equivalent.
    6.  
    7. Press the mainshaft, drum and output flange from the case.
    8.  
    9. Remove the speedometer drive gear from the case.
    10.  
    11. Using tools D80L-1002-2, D79L-4621-A and D80L-630-6, remove the outer bearing cone from the mainshaft.
    12.  
    13. Place the threaded end of the output shaft in a soft-jawed vise.
    14.  
    15. Matchmark the drum, flange/yoke and mainshaft. Remove the 4 nuts securing the flange and drum to the output shaft and remove the flange and drum.
    16.  
    17. Using tool T77F-1102-A, remove the input shaft oil seal, spacer, O-ring, bearing cone and race from the input shaft end of the case.
    18.  
    19. Remove the 4 bolts securing the splash shield and brake assembly from the case. Remove the brake assembly and splash shield.
    20.  
    21. Remove the brake actuating lever and spring from the case.
    22.  
    23. Using tool T77F-1102-A, remove the outer bearing cup and oil seal.
    24.  
    25. Unscrew the vent from the case.
    26.  
    27. Hold the brake assembly securely and remove the 2 brake sure return springs.
    28.  
    29. Spread the free ends of the shoes and remove the shoes from the lower anchor pin. Remove the shoe-to-shoe spring.
    30.  

    ASSEMBLY



    See Figures 8 and 9



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    Fig. Fig. 8: Exploded view of the F-Super Duty parking brake shoes



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    Fig. Fig. 9: Assembling the F-Super Duty parking brake shoes

    1. Clean the brake assembly thoroughly with a brake cleaning solvent.
    2.  
    3. Using a brake caliper grease, place a light coating on:

      Camshaft lugs and ball on the actuating lever
       
      Shoe guide lugs and support pads on the support plate
       
      Upper and lower anchor pins
       
      Brake shoe anchor pin contact points
       

    4.  

    1. Connect a NEW shoe-to-shoe spring between the brake shoes, spread the shoes and position them on the lower anchor pin.
    2.  
    3. Position the upper ends on the upper anchor pin, inserting the show webs between the shoe guide lugs and the pads on the support plate.
    4.  
    5. Install 2 NEW return springs.
    6.  
    7. Drive a new inner bearing race into place.
    8.  
    9. Drive a new outer bearing race into the case making sure it bottoms evenly.
    10.  
    11. Install a new outer bearing.
    12.  
    13. Coat the outer edge of a new outer oil seal with sealer and drive the seal into place with the lip facing inward. The seal must be flush with the bore surface.
    14.  
    15. Install the actuating lever spring.
    16.  
    17. Apply a light coating of brake grease on the actuating lever ball and install the lever through the coiled end of the spring.
    18.  
    19. Position the brake assembly into the case. Insert the lever into position in the brake assembly.
    20.  
    21. Tighten the 4 brake assembly attaching bolts to 90 ft. lbs. (122 Nm).
    22.  
    23. Attach the retracting spring to the actuating lever while bending the long end to snap over the lever.
    24.  
    25. Place the mainshaft in a soft-jawed vise with the flanged end upward.
    26.  
    27. Install the brake drum and output flange onto the mainshaft, being aware of the matchmarks.
    28.  
    29. Install the 4 nuts and tighten them to 85 ft. lbs. (115 Nm).
    30.  
    31. Turn the mainshaft over and clamp it in the vise.
    32.  
    33. Install the case, with the outer bearing installed loosely on the mainshaft, guiding the mainshaft through the oil seal and bearing cone.
    34.  
    35. Install the outer bearing cone on the mainshaft using tool T88T-2598-F, or equivalent, to seat the bearing on the shaft.
    36.  
    37. Install the speedometer gear and snapring.
    38.  
    39. Install the shim on the mainshaft.
    40.  

    This shim determines end-play. It is available in several thicknesses with variations of 0.0019 in. (0.05mm).

    1. Install the inner bearing cone and spacer on the mainshaft.
    2.  

    To check end-play, first install the inner bearing spacer without the O-ring.

    1. Thread the 75mm nut onto the shaft and tighten it to 215 ft. lbs. (292 Nm).
    2.  
    3. Mount a dial indicator and bracket with the dial indicator between the mainshaft and case to check end-play. While rotating the case assembly on the mainshaft to center the bearings, apply pressure up and down. An end-play reading of 0.0019-0.0039 in. (0.05-0.10mm) is desired. Shim as necessary.
    4.  
    5. Remove the 75mm nut, spacer and bearing to install the shim(s).
    6.  
    7. Install the bearing.
    8.  
    9. Coat the outer edge of a new seal with sealer and seat it in the case bore with the lip facing inward.
    10.  
    11. Install a new O-ring in the spacer and install the spacer on the mainshaft until it butts against the shoulder of the shaft.
    12.  
    13. Install a NEW 75mm nut and tighten it to 215 ft. lbs. (292 Nm).
    14.  
    15. Install the vent.
    16.  

    INSTALLATION



    See Figures 10, 11, 12, 13, 14 and 15

    1. Refill the unit through the filler plug to the bottom of the plug hole. Install the plug and tighten it to 45 ft. lbs. (61 Nm).
    2.  
    3. Position the unit on the extension housing using 2 guide pins.
    4.  
    5. Using 6 NEW hex-bolts, attach the unit and tighten the bolts to 40 ft. lbs. (54 Nm).
    6.  
    7. Connect the driveshaft and tighten the bolts to 20 ft. lbs. (27 Nm).
    8.  
    9. Assemble the cable components. Screw on the clevis until the pin can be inserted while the lever and cable are held tightly in the applied position. Then, remove the pin, let go of the cable and lever, and turn the clevis 10 full turns counterclockwise (loosen).
    10.  
    11. Install the pin.
    12.  

    ADJUSTMENT



    1. Fully release the brake pedal.
    2.  
    3. Spray penetrating oil on the adjusting clevis, jam nut and threaded end of the cable.
    4.  
    5. Loosen the jam nut and remove the locking pin from the clevis.
    6.  
    7. Back off on the clevis until there is slack in the cable.
    8.  
    9. Screw on the clevis until the pin can be inserted while the lever and cable are held tightly in the applied position. Then, remove the pin, let go of the cable and lever, and turn the clevis 10 full turns counterclockwise (loosen).
    10.  
    11. Install the pin.
    12.  



    Click image to see an enlarged view

    Fig. Fig. 10: Installing the F-Super Duty actuating lever



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    Fig. Fig. 11: Installing the speedometer drive gear on the F-Super Duty parking brake



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    Fig. Fig. 12: Installing the inner bearing cone and shim on the F-Super Duty parking brake



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    Fig. Fig. 13: Measuring end-play on the F-Super Duty parking brake



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    Fig. Fig. 14: Installing the inner seal on the F-Super Duty parking brake



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    Fig. Fig. 15: F-Super Duty parking brake adjustment points

     
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