Saturn Coupes/Sedans/Wagons 1991-1998 Repair Guide

Cables

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REMOVAL & INSTALLATION



Except Equalizer Cable

See Figures 1 and 2

  1. Disconnect the negative battery cable. If equipped, disable the air bag system.
  2.  
  3. Remove the center console assembly from the vehicle. For center console removal procedures, refer to Body & Trim .
  4.  
  5. Remove the adjuster nut and, if present, the spring from the threaded rod, then disengage the cables from the equalizer assembly.
  6.  
  7. Using SA9151BR or an equivalent release tool, remove the brake cable from the parking brake base bracket.
  8.  

Before removing the cable from the vehicle, tie a piece of wire or string to the console end of the cable. After removal, the string can be used to pull the new cable through the floor pan and into position.

  1. Remove the rear seat cushion and pull back the carpeting.
  2.  
  3. Raise the rear of the vehicle and support it safely using jackstands, then remove the rear wheels.
  4.  
  5. Remove the cable grommet/cable assembly from the floor pan. Then, remove the trailing arm/parking brake cable-to-body fasteners.
  6.  
  7. Cut and remove the brake cable retaining tie strap.
  8.  
  9. If equipped with drum brakes, proceed as follows:
    1. Remove the brake drum. Refer to the procedure earlier in this section.
    2.  
    3. Remove the lower return spring and the adjuster spring.
    4.  
    5. Remove the parking brake shoe hold-down cup assembly.
    6.  
    7. Pull the parking brake shoe towards the rear of the vehicle and remove the adjuster assembly.
    8.  
    9. Disconnect the upper return spring from the parking brake shoe.
    10.  
    11. Remove the parking brake cable from the parking brake lever and remove the parking brake cable spring.
    12.  
    13. Use SA9151BR or an equivalent cable release tool to remove the cable from the backing plate.
    14.  

  10.  
  11. If equipped with disc brakes, proceed as follows:
    1. Remove the nut securing the cable to the floor pan stud.
    2.  
    3. Use SA9151BR or an equivalent cable release tool to remove the cable from the caliper lever.
    4.  

  12.  
  13. Remove the cable from the vehicle.
  14.  

To install:
  1. If equipped with disc brakes, proceed as follows:
    1. Install the parking brake cable into the caliper bracket and correctly seat the retaining fingers.
    2.  
    3. Attach the cable to the caliper park brake lever.
    4.  
    5. Install the trailing arm/parking brake cable-to-body fasteners, then tighten the fasteners to 89 ft. lbs. (120 Nm).
    6.  
    7. Install the cable bracket to the floor pan stud. Install the nut and tighten to 25 inch lbs. (2.8 Nm).
    8.  

  2.  
  3. If equipped with drum brakes, proceed as follows:
    1. Install the cable through the brake backing plate and correctly seat the retaining fingers.
    2.  
    3. Install the cable spring onto the cable, then install the cable end into the actuator lever.
    4.  
    5. Connect the short end of the upper return spring to the leading brake shoe, then connect the other end of the spring to the parking brake shoe.
    6.  
    7. Pull the parking brake shoe toward the vehicle' rear and install the adjuster assembly between the shoes, then install the adjuster lever.
    8.  
    9. Install the adjuster spring with the short end into the leading shoe and the other end into the adjuster lever.
    10.  
    11. Install the lower return spring, then install the parking brake shoe hold-down cup assembly.
    12.  
    13. Adjust the brake shoe outer diameter to 0.02 in. (0.50mm) less than the inner diameter of the brake drum and install the brake drum.
    14.  
    15. Install the trailing arm/parking brake cable-to-body fasteners, then tighten the fasteners to 89 ft. lbs. (120 Nm).
    16.  

  4.  
  5. Pull the cable into the vehicle with the wire or string that was attached during disassembly.
  6.  
  7. Install the grommet into the floor pan.
  8.  
  9. Install the rear wheels.
  10.  
  11. Install the cables into the parking brake base bracket, then attach the cables to the equalizer.
  12.  

On 1991-94 models, refer to the appropriate illustration for equalizers of the first production design; on these models, the cable entry holes (rounded side of the equalizer) must face downward. For the second design, the cable entry holes may face up or down.

  1. Install the cable and equalizer assembly onto the threaded rod, then install the adjusting nut.
  2.  
  3. For rear drum brake equipped vehicles, apply and release the brake pedal 20 times to allow the drum brake adjuster to position the brake shoes.
  4.  
  5. Adjust the parking brake; refer to the procedure later in this section.
  6.  
  7. Place the carpet back to its original position. Install the center console and the rear seat cushion.
  8.  
  9. Remove the supports and carefully lower the vehicle to the ground.
  10.  
  11. Enable the air bag system and connect the negative battery cable.
  12.  



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Fig. Fig. 1: Remove the brake cable from the console bracket



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Fig. Fig. 2: Two equalizer designs have been used in 1991-94 Saturn production; the first design must be installed with the curved side downward

Equalizer Cable
1995-98 MODELS
  1. Disconnect the negative battery cable. Disable the air bag system, as described in Chassis Electrical .
  2.  
  3. Remove the center console assembly from the vehicle. For center console removal procedures, refer to Body & Trim .
  4.  
  5. Remove the cable adjuster nut located on the parking brake lever.
  6.  
  7. Disengage the rear cables from the equalizer assembly.
  8.  
  9. Pull up the parking brake lever to its highest position.
  10.  
  11. Move the equalizer cable over the parking brake indicator switch and swing it forward. Pull the cable down and out of the parking brake lever.
  12.  

To install:
  1. Route the equalizer cable into the parking brake lever and start the adjuster nut by hand.
  2.  
  3. Swing the equalizer cable rearward and lift it over the parking brake indicator switch.
  4.  
  5. Release the parking brake lever to the fully lowered position.
  6.  
  7. Install both of the rear cables into the equalizer.
  8.  
  9. Adjust the parking brake; refer to the procedure later in this section.
  10.  
  11. Install the center console assembly; refer to Body & Trim .
  12.  
  13. Enable the air bag system and connect the negative battery cable.
  14.  

ADJUSTMENT



See Figures 3, 4, 5, 6, 7, 8 and 9

If equipped with rear drum brakes that have been serviced, before performing parking brake adjustment procedures, apply and release the brake pedal 20 times. This allows the adjuster to position the brake shoes and prevents premature wear of the brake linings due to improper parking brake adjustment.

  1. Disconnect the negative battery cable.
  2.  
  3. On 1991 models, remove the center console assembly; refer to Body & Trim for removal procedures. On 1992-94 models, remove the center console rear ashtray. On 1995-98 models, lift up the brake lever, remove the cover retaining screw and slide the cover off.
  4.  
  5. Raise the rear of the vehicle and support it safely using jackstands.
  6.  
  7. On 1991-94 models, pull the brake lever up to the 3rd click from the released position. On 1995-98 models, pull the brake lever up to the 1st click from the released position.
  8.  
  9. Tighten the adjuster nut until a slight brake drag is felt at the rear wheels.
  10.  
  11. Apply and release the lever several times.
  12.  
  13. Pull the lever up to the 2nd click. There should be no brake drag at the rear wheels.
  14.  
  15. Pull the lever to the 3rd click and check for a slight drag at the rear wheels.
  16.  
  17. Pull the lever to the 4th click and verify that the rear wheels are locked (they cannot be turned by hand).
  18.  
  19. Loosen or tighten the adjuster nut as necessary until these conditions are met.
  20.  
  21. On 1991-94 models, if the proper adjustment cannot be obtained, perform the following:
    1. Check measurement A, from the center of the pivot pin attachment to the end of the adjuster rod, as shown in the appropriate illustration.
    2.  
    3. If the measurement is 5.78 in. (147mm) or less, replace the brake lever assembly.
    4.  
    5. If the measurement is 6.33 in. or more, check for damage or incorrect installation of the drum brake assembly components, parking brake cables and/or parking brake lever assembly.
    6.  

  22.  
  23. Install the center console assembly, ashtray or parking brake lever cover, if applicable.
  24.  
  25. Remove the supports, lower the vehicle and connect the negative battery cable.
  26.  



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Fig. Fig. 3: On 1992-94 models, insert a small prytool between the console and ashtray ...



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Fig. Fig. 4: ... to disengage and remove the ashtray assembly



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Fig. Fig. 5: Pull the brake lever up from the released position



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Fig. Fig. 6: An ashtray opening at the rear of the console provides convenient access to the parking brake adjustment



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Fig. Fig. 7: Tighten the adjuster nut until a slight brake drag is felt at the rear wheels



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Fig. Fig. 8: When properly adjusted, these conditions should be observed while attempting to turn the rear wheel by hand, depending on parking brake lever position



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