Chrysler Full-Size Trucks 1967-1988 Repair Guide

Cables

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CAUTION
Brake shoes 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.

REMOVAL & INSTALLATION



Rear Wheel Internal Expanding
1967-72 FRONT
  1. Raise and support the truck on jackstands.
  2.  
  3. Disconnect the front cable return spring at the equalizer.
  4.  
  5. Remove the adjusting nut at the equalizer.
  6.  
  7. Disconnect the cable housing at the lower anchor point and remove the cable and housing from the bracket.
  8.  
  9. Remove the bolt from the cable housing anchor clip at the parking brake lever.
  10.  
  11. Remove the clevis pin at the lever.
  12.  
  13. Remove the anchor clip from the cable housing.
  14.  
  15. Remove the housing grommet from the firewall and cable assembly by pushing the grommet forward, towards the engine.
  16.  

To install:
  1. Install the housing grommet in the firewall.
  2.  
  3. Install the anchor clip on the cable housing.
  4.  
  5. Install the clevis pin at the lever.
  6.  
  7. Install the bolt from the cable housing anchor clip at the parking brake lever.
  8.  
  9. Install the cable and housing at the bracket. Connect the cable housing at the lower anchor point.
  10.  
  11. Install the adjusting nut at the equalizer.
  12.  
  13. Connect the front cable return spring at the equalizer.
  14.  
  15. Adjust the parking brake.
  16.  

1973-88 FRONT

See Figures 1 and 2

  1. Raise and support the rear end on jackstands.
  2.  
  3. Remove the adjusting nut at the equalizer.
  4.  



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Fig. Fig. 1: Hold the threaded cable end steady while loosening the adjusting nut



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Fig. Fig. 2: Most equalizer assemblies divide the front/intermediate cable load across the 2 rear cables

  1. Disengage the cable housing at the lower anchor point and remove the cable and housing from the bracket.
  2.  
  3. Remove the cable housing anchor clip at the parking brake lever.
  4.  
  5. Remove the anchor clip from the lever.
  6.  
  7. Remove the housing grommet from the floor board.
  8.  

To install:
  1. Install the cable and housing through the floor pan and install the housing grommet.
  2.  
  3. Install the anchor clip on the cable housing.
  4.  
  5. Connect the cable at the adjusting link by installing the adjusting nut.
  6.  
  7. Adjust the parking brake.
  8.  
  9. Adjust the brakes.
  10.  

1979-83 INTERMEDIATE CABLE
  1. Raise and support the vehicle enough to gain access to the equalizer and cable adjustment.
  2.  
  3. Release parking brake.
  4.  
  5. Remove the adjusting nut at the adjusting link.
  6.  
  7. Disengage the rear end of the cable from the ratio lever and remove the cable.
  8.  
  9. Remove the ratio lever pivot bolt nut and bolt.
  10.  
  11. Disengage the front of the ratio lever rod from ratio lever assembly.
  12.  
  13. Remove the rod from the equalizer.
  14.  

To install:
  1. Install the rod to the equalizer.
  2.  
  3. Engage the front of the ratio lever rod to the ratio lever assembly.
  4.  
  5. Reinstall the ratio lever pivot bolt nut and bolt.
  6.  
  7. Replace the cable and engage the rear end of the cable to the ratio lever.
  8.  
  9. Install the adjusting nut at the adjusting link.
  10.  
  11. Adjust the brakes.
  12.  
  13. Lower the vehicle, test the parking brake system.
  14.  

1984-88 INTERMEDIATE CABLE
  1. Raise and support the vehicle enough to gain access to the equalizer and cable adjustment.
  2.  
  3. Release parking brake.
  4.  
  5. Remove the adjusting nut at adjusting link.
  6.  
  7. Disengage the rear end of cable from the ratio lever or cable equalizer and remove.
  8.  

To install:
  1. Replace the rear end of cable onto the ratio lever or equalizer.
  2.  
  3. Insert the adjusting nut onto link.
  4.  
  5. Adjust the brakes. Lower the vehicle.
  6.  
  7. Test the brake system.
  8.  

1967-72 REAR CABLE
  1. Raise and support the vehicle.
  2.  
  3. Release the brake and remove the rear wheels.
  4.  
  5. Remove the brake drum.
  6.  
  7. Remove the brake shoe return springs.
  8.  
  9. Remove the brake shoe retaining springs.
  10.  
  11. Remove the brake shoes, strut and spring from the support plate.
  12.  
  13. Disconnect the brake cable from the operating arm.
  14.  
  15. Compress the retainers on the end of the brake cable housing and remove the cables from the brake support plate.
  16.  
  17. Remove the retaining bolt and nut from the brake cable bracket and clips at the front bracket.
  18.  
  19. Disconnect the brake cable at the equalizer bar.
  20.  
  21. Remove the cable assembly.
  22.  
  23. Installation is the reverse of removal. Adjust the brakes.
  24.  

1973-88 REAR CABLE
  1. Raise and support the rear end on jackstands.
  2.  
  3. Remove the rear wheels.
  4.  
  5. Remove the drums.
  6.  
  7. Remove the brake shoe return springs.
  8.  
  9. Remove the brake shoe retaining springs.
  10.  
  11. Remove the shoes, strut and spring from the support plate.
  12.  
  13. Disconnect the cable from the operating arm.
  14.  
  15. Compress the retainers on the end of the cable housing and remove the cable from the support plate.
  16.  
  17. Move the retaining clip out at the crossmember.
  18.  
  19. Disconnect the brake cable from the equalizer.
  20.  

To install:

Before installing the new brake cable lubricate it with short fiber grease at all contact points.

  1. Insert the cable and housing into the crossmember, and install the retaining clip.
  2.  
  3. Insert the brake cable and housing into the brake support plate making sure the housing retainers lock the housing firmly into place.
  4.  
  5. Holding brake shoes (and the strut, if equipped) in place on the support table. Engage the brake cable into the brake shoe operating lever.
  6.  
  7. Install the brake shoe retaining springs, and return springs.
  8.  
  9. Insert the front cable into the equalizer. Install the drum and wheel.
  10.  
  11. Adjust the brakes and parking cable.
  12.  

ADJUSTMENT



Wheel Mounted
  1. Adjust the service brakes by making a few stops in reverse.
  2.  
  3. Raise and support the rear end on jackstands.
  4.  
  5. Release the parking brake lever and loosen the cable adjusting nut to be sure that the cable is slack.
  6.  
  7. Tighten the cable adjusting nut until a slight drag is felt while rotating the wheels.
  8.  
  9. Loosen the cable adjusting nut until the wheels can be rotated freely, then back off the cable adjusting nut two turns.
  10.  
  11. Apply the parking brake several times, then release it and check to be sure that the rear wheels rotate freely.
  12.  

Transmission/Transfer Case Mounted
EXTERNAL CONTRACTING
  1. Check the free play between the anchor bracket on the band and the anchor. Free play should not exceed 0.005 in. (0.12mm). If it does, remove the anchor bracket and compress it in a vise. Install it and recheck. Keep at it until you get it right.
  2.  
  3. Place the parking brake lever in the fully released position.
  4.  
  5. Adjust the anchor bolt to give a clearance of 0.015-0.020 in. (0.38-0.50mm) between the lining and the drum.
  6.  
  7. Install a lockwire on the anchor bolt, but don't pull it tight.
  8.  
  9. Adjusting the guide bolt adjusts the lower half of the band; adjusting the nut adjusts the upper half. Adjust each until there is equal drag on both the lower and upper half with each having equal clearance.
  10.  
  11. To adjust the cable, loosen the locknut, remove the clevis pin and turn the yoke until all slack is removed from the cable.
  12.  

INTERNAL EXPANDING

If the adjustment is not performed correctly, shifting of the transmission will be affected.

  1. Place the shift lever in NEUTRAL.
  2.  
  3. Fully release the parking brake.
  4.  
  5. Disconnect the driveshaft at the drum.
  6.  
  7. Remove the adjusting screw cover plate.
  8.  
  9. Loosen the brake cable clamp bolt and back off the cable adjusting nut.
  10.  
  11. Turn the nut to increase drag on the drum until a slight drag is felt, then, back off the nut one full notch.
  12.  

Make sure that the two raised shoulders on the adjusting nut are seated in the grooves on the adjusting sleeve.

  1. The cable length adjusting nut should be positioned against the cable housing so that there is 0.005-0.010 in. (0.12-0.25mm) clearance between the operating lever and the brake shoe cable.
  2.  
  3. To lock the adjustment, tighten the cable housing clamp securely.
  4.  
  5. Tighten the cable adjusting nut against the housing.
  6.  
  7. Check the parking brake lever travel.
  8.  
  9. Install the cover plate.
  10.  
  11. Connect the driveshaft.
  12.  
  13. Apply the parking brakes several times, then release and test to see if the rear wheels are rotating freely without dragging.
  14.  

Brake Band Replacement
EXTERNAL CONTRACTING

See Figure 3

  1. Raise and support the front end on jackstands.
  2.  
  3. Disconnect the parking brake cable.
  4.  
  5. Unscrew and remove the adjusting nut.
  6.  
  7. Remove the guide bolt adjusting locknuts.
  8.  
  9. Remove the anchor adjusting screw.
  10.  
  11. Pull the band assembly away from the transmission and off the driveshaft.
  12.  
  13. Installation is the reverse of removal. Adjust the brake.
  14.  

INTERNAL EXPANDING

See Figures 4 and 5

  1. Disconnect the driveshaft at the transmission.
  2.  
  3. Remove the companion flange nut, lockwasher and flatwasher.
  4.  
  5. Install a puller on the companion flange and remove the flange and drum. You'll have to devise a method of holding the unit to keep it from turning while pulling the drum.
  6.  
  7. Disengage the cable from the operating lever.
  8.  
  9. Separate the shoes at the bottom, allowing the shoe adjusting nut screws and sleeve to drop out and release the shoes.
  10.  
  11. Pry the brake shoe return spring up and over to the right and pry the brake shoe inward.
  12.  
  13. Remove the spring from the assembly.
  14.  
  15. Pry out the brake shoe retaining washer and remove the outer guide.
  16.  
  17. Slide each shoe out from under the guide spring. As the shoes are removed, the operating lever will drop out of place.
  18.  
  19. Separate the operating lever from the right shoe by removing the nut, lockwasher and bolt.
  20.  

To assemble:
  1. Assemble the operating lever on the right shoe.
  2.  
  3. Slide the right and left shoes under the guide.
  4.  
  5. Spread the shoes and insert the operating lever.
  6.  
  7. Work the return spring under the guide and upward to engage the retaining pin on the left shoe.
  8.  
  9. Force the other end of the return spring upward and over the retaining pin on the right shoe.
  10.  
  11. Spread the shoes apart at the bottom and install the adjusting nut, screw and sleeve.
  12.  
  13. Place the anchor guide over the anchor and secure the shoes with the retaining washer.
  14.  
  15. Turn the brake shoe adjusting nut until the shoes are in a released position and install the brake drum.
  16.  
  17. Make sure that the brake shoes are centered on the backing plate and are free to move.
  18.  
  19. Install the brake drum, washers and nut. Tighten the nut to 35 ft. lbs. (47 Nm).
  20.  
  21. Adjust the shoes and cable.
  22.  

Parking Cable Routing

See Figures 6 through 13

Parking brake cables are routed a little different for each year and model vehicle. But there are a many similarities across the line of trucks. Most importantly, make sure cables are routed without interference from suspension or drivetrain parts. Also, be sure the cables are not routed too closely to the exhaust system. Refer to the following illustrations for common views of cable routings, clip and bracket locations. This will help you to determine the proper routing for your truck.



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Fig. Fig. 3: External contracting parking brake



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Fig. Fig. 4: Internal expanding



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Fig. Fig. 5: Control cable adjustment



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Fig. Fig. 6: 1973-76 rear cable routing



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Fig. Fig. 7: 1973-76 front cable routing



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Fig. Fig. 8: 1977-80 cable routing



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Fig. Fig. 9: 1981-83 cable routing



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Fig. Fig. 10: 1984 cable routing



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Fig. Fig. 11: 1985-87 cable routing



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Fig. Fig. 12: 1988 brake cable routing



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Fig. Fig. 13: 1988 brake cable routing-continued

 
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