AutoZone 2005 Chevrolet Truck Astro Van AWD 4.3L SFI OHV 6cyl | Repair Guides | Brakes | Parking Brake | Cable | AutoZone.com

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    2005 Chevrolet Truck Astro Van AWD 4.3L SFI OHV 6cyl

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    Ford Ranger/Explorer/Mountaineer 1991-1999

    Cable

    Print

    ADJUSTMENT



    1991-92 models
    PRE-TENSION PROCEDURE

    See Figure 1



    Click image to see an enlarged view

    Fig. Fig. 1: Pre-tension adjustment

    This procedure is to be used when a new Tension Limiter has been installed.

    1. Depress the parking brake pedal.
    2.  
    3. Grip the Tension Limiter Bracket to prevent it from spinning and tighten the equalizer nut 2 1 / 2 in. (63.5mm) up the rod.
    4.  
    5. Check to make sure the cinch strap has slipped less than 1 3 / 8 in. (35mm) remaining.
    6.  

    FINAL ADJUSTMENT

    This procedure is to be used to remove the slack from the system if a new Tension Limiter has not been installed.

    1. Make sure the brake drums are cold for correct adjustment.
    2.  
    3. Position the parking brake pedal to the fully depressed position.
    4.  
    5. Grip the threaded rod to prevent it from spinning and tighten the equalizer nut 6 full turns past its original position on the threaded rod.
    6.  
    7. Attach an appropriate cable tension gauge (Rotunda Model 21-0018 or equivalent) behind the equalizer assembly either toward the right or left rear drum assembly and measure cable tension. Cable tension should be 40-600 lbs. with the parking brake pedal fully in the last detent position. If tension is low, repeat Steps 2 and 3.
    8.  
    9. Release parking brake and check for rear wheel drag. The cables should be tight enough to provide full application of the rear brake shoes, when the parking brake lever or foot pedal is placed in the fully applied position, yet loose enough to ensure complete release of the brake shoes when the lever is in the released position.
    10.  

    The Tension Limiter will reset the parking brake tension any time the system is disconnected provided the distance between the bracket and the cinch strap hook is reduced during adjustment. When the cinch strap contacts the bracket, the system tension will increase significantly and over tensioning may result. If all available adjustment travel has been used, the tension limiter must be replaced.

    1993-99 Models

    Starting in 1993, all models use a self-adjusting parking brake cable assembly. However, in order to remove any of the cables or components, the following procedures must be followed.

    CABLE TENSION RELEASE

    See Figure 2



    Click image to see an enlarged view

    Fig. Fig. 2: With the parking brake released, insert the pin into the brake control assembly as shown to lock the cable tension spring

    Method 1:
    1. Place the parking brake cable control in the released position.
    2.  
    3. Have an assistant pull on the intermediate brake cable while you insert a 5 / 32 in. (4mm) diameter steel pin (or drill bit) into the hole provided in the parking brake control assembly.
    4.  
    5. To release the cable tension, pull out the lock pin from the control assembly.
    6.  

    Method 2:

    For relieving tension from the rear cables only.

    1. Pull backwards on the rear cable and conduit about 1.0-2.0 in. (25-50mm) and place a clamp on the parking brake cable and conduit behind the rear crossmember.
    2.  


    WARNING
    Ensure that you do not damage the nylon coating on the cable.

    1. To release the cable tension, remove the clamp holding the rear cable to the crossmember.
    2.  

    CABLE TENSION RESETTING

    See Figures 3, 4, 5 and 6



    Click image to see an enlarged view

    Fig. Fig. 3: Exploded view of the parking brake control assembly mounting

    In the event that one of the cables has broken, or the cable tension release procedures were not followed perform the following procedures:

    1. Remove the parking brake control assembly.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 4: Engage the coil spring to the tab on the adjusting wheel

    1. Engage the coil spring to the tab on the adjusting wheel in the control assembly.
    2.  
    3. Ensure the control assembly is in the released position.
    4.  



    Click image to see an enlarged view

    Fig. Fig. 5: Slip the front parking brake cable around the pulley and insert the cable end to the ratchet plate

    1. Slip a spare front parking brake (or remove you existing one) cable around the pulley and insert the cable end into the pivot hole in the ratchet plate.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 6: While stepping on the cable end, pull upwards on the control assembly then install the lock pin when the holes align

    1. Position the free end of the parking brake cable on the floor and step on it, or clamp it in a vise.
    2.  
    3. Pull on the control assembly, holding the mounting bracket tightly against the body of the control, until the cable tension rotates the cable track assembly so that the (lock pin) 5 / 32 in. (4mm) diameter steel pin (or drill bit) can be fully seated through the plate.
    4.  
    5. Insert the lock pin so that the assembly is in the "cable released" position.
    6.  
    7. Install the parking brake control lever.
    8.  

    REMOVAL & INSTALLATION



    See Figures 7 and 8



    Click image to see an enlarged view

    Fig. Fig. 7: Ranger and 1991-94 Explorer parking brake cable routing diagram



    Click image to see an enlarged view

    Fig. Fig. 8: Mountaineer and 1995-99 Explorer parking brake cable routing diagram

    Equalizer-To-Control Cable
    1. Raise the vehicle on a hoist and support on jackstands.
    2.  
    3. On 1991-92 models, back off the equalizer nut and remove slug of front cable from the tension limiter.
    4.  
    5. On 1993-99 models, relieve the parking brake cable tension as outlined under cable adjustments.
    6.  
    7. Remove the parking brake cable from the bracket.
    8.  
    9. Remove the jackstands and lower the vehicle. Remove the forward ball end of the parking brake cable from the control assembly clevis.
    10.  
    11. Remove the cable from the control assembly.
    12.  
    13. Using a fishing line wire leader or cord attached to the control lever end of the cable, remove the cable from the vehicle.
    14.  

    To install:
    1. Transfer the fish wire or cord to the new cable. Position the cable in the vehicle, routing the cable through the dash panel. Remove the fish wire and secure the cable to the control.
    2.  
    3. Connect the forward ball end of the brake cable to the clevis of the control assembly. Raise the vehicle on a hoist.
    4.  
    5. Route the cable through the bracket.
    6.  
    7. Connect the slug of the cable to the Tension Limiter connector.
    8.  
    9. On 1991-92 models, adjust the parking brake cable at the equalizer using the appropriate procedure shown above.
    10.  
    11. On 1993-99 models, release the cable tension as outlined under cable adjustments.
    12.  
    13. Rotate both rear wheels to be sure that the parking brakes are not dragging.
    14.  

    Equalizer-To-Rear Wheel Cables
    EXCEPT REAR DISC BRAKE

    See Figure 9



    Click image to see an enlarged view

    Fig. Fig. 9: View of the rear brake cable mounting assembly

    1. Raise the vehicle and remove the wheel and brake drum.
    2.  
    3. On 1991-92 models, remove the locknut on the threaded rod and disconnect the cable from the equalizer.
    4.  
    5. On 1993-99 models, relieve the parking brake cable tension as outlined under cable adjustments. Disconnect the left rear cable from the front cable. For the right rear cable, disconnect it from the cable equalizer and rear guide bracket.
    6.  
    7. Use a 9 / 16 in. (14mm) wrench and compress the prongs that retain the cable housing to the frame bracket, and pull the cable and housing out of the bracket.
    8.  
    9. Working on the wheel side, use a 9 / 16 in. (14mm) wrench and compress the prongs on the cable retainer so they can pass through the hole in the brake backing plate. Draw the cable retainer out of the hole.
    10.  
    11. With the spring tension off the parking brake lever, lift the cable out of the slot in the lever, and remove the cable through the brake backing plate hole.
    12.  

    To install:
    1. Route the right cable behind the right shock and through the hole in the left frame side rail. Route the left cable inboard of the leaf spring. Pull the cable through the brake backing plate until the end of the cable is inserted over the slot in the parking brake lever. Pull the excess slack from the cable and insert the cable housing into the brake backing plate access hole until the retainer prongs expand.
    2.  
    3. Insert the front of the cable housing through the frame crossmember bracket until the prong expands. Insert the ball end of the cable into the key hole slots on the equalizer, rotate the equalizer 90° and recouple the Tension Limiter threaded rod to the equalizer.
    4.  
    5. Install the rear brake drum and wheel, and adjust the rear brake shoes.
    6.  
    7. On 1991-92 models, adjust the parking brake tension using the appropriate procedure shown above.
    8.  
    9. On 1993-99 models, release the cable tension as outlined under cable adjustments.
    10.  
    11. Rotate both rear wheels to be sure that the parking brakes are not dragging.
    12.  
    13. Lower the vehicle and tighten the wheel lug nuts to 100 ft. lbs. (135 Nm).
    14.  

    REAR DISC BRAKE

    See Figure 10



    Click image to see an enlarged view

    Fig. Fig. 10: View of the rear disc parking brake cable mounting

    1. Loosen the rear wheel lug nuts.
    2.  
    3. Raise the rear of the vehicle and remove the wheel.
    4.  
    5. Relieve the parking brake cable tension as outlined under cable adjustments.
    6.  
    7. Disconnect the left rear cable from the front cable. For the right rear cable, disconnect it from the cable equalizer and rear guide bracket.
    8.  
    9. Use a 9 / 16 in. (14mm) wrench and compress the prongs that retain the cable housing to the frame bracket, and pull the cable and housing out of the bracket.
    10.  
    11. Lift the parking brake rear cable eyelet off of the parking brake lever at the rear disc brake backing plate.
    12.  
    13. Compress the retainer fingers at the caliper adapter bracket with a 1 / 2 in. (13mm) box end wrench and remove the parking brake cable through the hole in the bracket.
    14.  

    To install:
    1. Hook the cable eyelet over the parking brake lever. Push back the spring and put the exposed cable through the slot in the backing plate bracket.
    2.  
    3. Push the cable housing end into the bracket to engage the retainer fingers.
    4.  
    5. Route the cable along its original path.
    6.  
    7. For the right rear cable, insert the cable end through the rear guide bracket until the retainer fingers engage.
    8.  
    9. Connect the rear cables back to their original positions.
    10.  
    11. Release the cable tension as outlined under cable adjustments.
    12.  
    13. Install the wheel and, if necessary, adjust the rear parking brake shoes.
    14.  
    15. Rotate both rear wheels to be sure that the parking brakes are not dragging.
    16.  
    17. Lower the vehicle and tighten the wheel lug nuts to 100 ft. lbs. (135 Nm).
    18.  

     
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