CHAPTER 14 PARKING BRAKE

1 page INDEX1 PARKING BRAKE 14-1 14-143E-05 CHAPTER 14 PARKING BRAKE 1Models FA and FB with LF05S TROUBLESHOOTING...14-2 SPECIAL TOOLS...14-3 INSPECTION AND ADJUSTMENT...14-4 PARKING BRAKE...14-7 14 PARKING BRAKE CONTROL...14-15 FINAL INSPECTION AND ADJUSTMENT...14-18

14-2 PARKING BRAKE 1 page 1 TROUBLESHOOTING Symptom Possible cause Remedy Too much play noted on Excessively large drum-to-lining... Re-adjust the brake properly parking brake lever clearance Maladjusted control linkage...re-adjust Not enough braking force Excessively large drum-to-lining... Re-adjust clearance Maladjusted control linkage...re-adjust Burnt lining...repair or replace Worn lining...replace Shoes are too dirty with water, dust, etc.. Disassemble and clean Linings are soaked with oil...replace Linings get burnt easily Not enough drum-to-lining clearance... Re-adjust Shoe or drum is distorted...repair or replace Springs are broken...replace Can not keep the lever in full Over stroke of lever...adjust cable length stroke position Wear or broken ratchet...replace parts Lever does not return to running position during cold weather (below zero) Water inside the cable...replace the cable

1 page 1 PARKING BRAKE 14-3 SPECIAL TOOLS Prior to starting a parking brake overhaul it is necessary to have these special tools. Illustration Tool No. Tool name 09606-1060 REMOVER 09653-1370 HOOK 09665-1170 ADJUSTING TOOL

1 page 1 14-4 PARKING BRAKE INSPECTION AND ADJUSTMENT WARNING Failure to properly adjust the brake can result in personal injury and/or property damage. Fig. 1 30 kg SM14-061 1. LEVER STROKE 1. Pull the parking lever with approx. 30 kg (66 lb) force and count the number of clicks. If the lever stroke exceeds 8 clicks, adjust brake shoe clearance and control cable. 2. ADJUSTING SHOE CLEARANCE 1. Adjusting of Shoe clearance. Block the front wheels. NOTE: Be sure to apply wheel stoppers in the front tires. Fig. 2 SMAT-040 2. Jack up the rear axle off the ground and release the parking lever, rotate the drum by hand, and stop rotating the drum when the adjusting hole comes to the bottom side. Fig. 3 SM17-289 WARNING When jacking up the rear axle, place a jack correctly to the axle, and then lift up the axle. Do not get under the vehicle when it is supported by a jack only. It is very dangerous as the jack might slip. Use safety stands which have sufficient strength and stability to support the vehicle. 3. Remove the rubber cap from the adjusting hole. Turn the adjuster in the arrow direction with a special tool inserted through the hole. Keep on turning the adjuster until the shoe linings bear against the drum to reduce the clearance to nought. Fig. 4 SM14-060 Special Tool: Adjusting Tool (09665-1170) NOTE: When adjusting shoe clearance, check the thickness of lining according to the THICK- NESS OF LINING on page 14-6.

1 page 1 PARKING BRAKE 14-5 4. Turn the adjuster backward by 10-12 notches, this will introduce the prescribed drum-to-lining clearance, the value of which is: Standard: Repair Limit: 0.30 0.35 mm (0.0119 0.0137 in.) 0.50 mm (0.0197 in.) Fig. 5 SM14-060 5. Check the adjustments so far made by operating the parking brake lever several times. Turn the drum by hand to see that the shoes are not dragging. If there is any dragging, repeat the operation from item 3.4. NOTE: Whenever the drum-to-lining clearance has to be readjusted be sure to follow the steps outlined above. Upon completing the foregoing adjustments, be sure to close the adjusting hole by fitting the rubber cap. Fig. 6 ADJUSTER ROD LOCK NUT SM14-145 3. ADJUSTING THE CONTROL PARTS 1. Adjust the L1 part of the parking brake cable to 33 mm (1.30 in.). 2. Perform the adjustment after item 1.1. 3. Release the parking brake lever fully. 4. Disconnect the control cable from the parking brake lever and adjust the control cable length by turning the adjuster rod. Connect the cable to the parking brake lever and lock the adjuster rod with the lock nut. L1 NOTE: When putting in a new replacement cable, be sure to pre-stress it so that it will not develop appreciable sag later. This can be accomplished by operating the parking brake lever with approx. 50kg (110.23 lb) force several times, with the new cable in place, before adjusting its tension as above. Fig. 7

14-6 PARKING BRAKE 1 page 1 Fig. 8 BUZZER SWITCH A A SM14-061 5. Check the parking brake lever stroke. Make sure that, when the lever is pulled all the way, with approx. 30 kg (66 lb) force, the dimension A will not take a value greater than what is indicated in the following table. If the dimension A is found to be greater, it means that the cable length is too long and needs readjustment. A = Parking lever stroke: 3 6 clicks 6. After adjusting, operate parking brake lever several times to confirm there is no dragging. 7. Adjust the parking buzzer switch. Adjust the A part of the parking switch to 5 mm(0.197 in.), when the parking brake lever is fully released, and confirm the indicator lamp lights, when the lever is applied by one notch. Fig. 9 Fig. 10 LIMIT 4 mm ADJUSTING HOLE RUBBER CAP SM14-046 SM14-146 WARNING Failure to properly adjust the brake can result in personal injury and/or property damage. 3. THICKNESS OF LINING 1. Every 36,000 miles, every 12 months or at the time of adjusting, check the thickness of lining. When the lining is worn, or when it is considered that it will be unserviceable for further use, replace the lining. 2. Bring adjusting hole of the drum to the groove at the center part of the lining which shows the life of lining as shown in the Fig. and measure the depth of groove to check the wear. No groove shows limit of life. Assembly Standard : 7.0 mm (0.276 in.) Service Limit : 4.0 mm (0.157 in.) 3. Connect the rubber cap which has been removed at checking securely. 4. Use of lining which exceeds service limit may cause the damage of drum because of damage or may lower the braking force.

1 page 1 PARKING BRAKE 14-7 PARKING BRAKE 2 3 4 5 6 1 9 8 7 15 10 16 14 17 13 12 11 1. Lever return spring 2. Anchor plate 3. Spacer 4. Camshaft 5. Shoe return spring 6. Rubber cap 7. Parking brake drum 8. Flange 9. Adjuster spring 10. Adjuster 11. Rivet 12. Lining 13. Brake shoe 14. Cable bracket 15. Spacer 16. Parking brake cam lever 17. Lever sub assembly Fig. 1 SM14-232A 1. REMOVAL 1. Dismount the propeller shaft. Disconnect the propeller shaft at flange of the parking brake. NOTE: Draw match marks on the flange and yoke before disconnecting. Fig. 2 SM14-116 2. Disconnect the parking brake cable from the brake lever. Fig. 3

14-8 PARKING BRAKE 1 page 1 3. Remove the drum. Remove the rubber cap from the adjusting hole. Bring the adjusting hole to the bottom side by turning drum. Turn the adjuster using a special tool, to contract the brake shoes. Special Tool: Adjusting Tool (09665 1170) Fig. 4 SM14-060 4. Loosen the fitting nuts. Fig. 5 SM14-117 5. Remove the parking brake drum. Before removing the brake drum, mark the drum and flange coupling so that the parts can be installed in the same relative position. Fig. 6 SM14-118 6. Remove the cotter pin, then loosen the lock nut. Fig. 7 SM14-119 7. Remove the flange coupling with spacer. Fig. 8 SM14-120

1 page 1 PARKING BRAKE 14-9 8. Loosen the four fitting bolts for parking brake anchor plate and then take out the brake assembly with anchor plate. Fig. 9 SM14-121 2. DISASSEMBLY 1. Remove the brake lever return spring. Fig. 10 2. Draw match marks on camshaft lever and camshaft across their serration fit. Fig. 11 3. Remove the lock bolt and lock nut of the lever and pull off the camshaft lever. Fig. 12 4. Remove the adjuster and adjuster spring. a. Expand the shoes by levering with screwdrivers, as shown, and remove the adjuster. b. Spread the shoes apart and remove the adjuster spring. Fig. 13 SM14-122

14-10 PARKING BRAKE 1 page 1 5. Remove two return springs by using a special tool. Special Tool: Remover (09606 1060) Fig. 14 Fig. 15 SM14-086 SM14-064 3. INSPECTION 1. Linings Check each lining for wear, and inspect it for cracks, tightness of rivets or signs of surface glazing. Repair linings as necessary. Linings deteriorated beyond repair must be replaced. (For the replacement of lining, refer to SECTION OF CHAPTER 13 SERV- ICE BRAKE). Standard: 7.0 mm (0.276 in.) Service limit: 4.0 mm (0.157 in.) 2. Check each shoe for wear particularly at its camshaft part and adjuster part, and also for alignment. Visually inspect it for cracks. ADJUSTER PART CAMSHAFT PART Fig. 16 3. Anchor plate and Drum cover Inspect the plate for distortion and cracks. Visually examine the seal part of the cover for distortion or damage. The surface of the seal part must be perfectly smooth, or water or dust may find its way into the brake resulting in a slipping brake or in premature failure of brake parts. Fig. 17 4. Camshaft Inspect the camshaft for cracks or wear. Fig. 18

1 page 1 PARKING BRAKE 14-11 5. Adjuster See if the threaded portion of the adjuster is rusted or otherwise damaged. Fig. 19 SM14-136 6. Springs Check each spring for elastic strength and inspect it for mechanical damage. The assembly standard of each spring is as follows. Fig. 20 SM14-137 Adjusting spring setting length: 74.0 mm (2.913 in.) setting load: 10.8 13.2 kg (23.82 29.1 lb) Shoe return spring setting length: 75.2 mm (2.961 in.) setting load: 16.6 20.4 kg (36.61 44.97 lb) Lever return spring setting length: 139 mm (5.472 in.) setting load: 15.4 18.8 kg (33.96 41.44 lb) 7. Parking brake drum Inspect and check for cracks, wear, out-of-round and burns on the parking brake drum. Observe the following reference values. A drum in too bad a condition to repair must be replaced. a. Check the parking brake drum inside diameter. Fig. 21 SM14-067 Standard: 254 mm (10.00 in.) Service Limit: 256 mm (10.07 in.) b. Check the parking brake drum for runout. Standard: Repair Limit: 0 0.1 mm (0 0.004 in.) 0.2 mm (0.008 in.) Fig. 22 SM14-068

14-12 PARKING BRAKE 1 page 1 4. ASSEMBLY 1. Apply the heat-resistance grease to the camshaft, and then install the camshaft. Heat-resistance grease: Refer to RECOMMENDED LUBRICANTS LIST. Fig. 23 2. Apply the heat-resistance grease to the rubbing or mating face of brake shoes, and install the brake shoes. Heat-resistance grease: Refer to RECOMMENDED LUBRICANTS LIST. Fig. 24 SM14-087 3. Raise the middle portions of shoes and install the spacer and return springs with the special tool. Special Tool: Hook (09653 1370) Fig. 25 SM14-088 4. Install the adjuster and adjuster spring. Apply the heat-resistance grease to the adjuster, and position the adjuster in place. Heat-resistance grease: Refer to RECOMMENDED LUBRICANTS LIST. Fig. 26 5. Install the camshaft lever with spacer to the camshaft, aligning the match marks. Secure them fit by tightening the securing bolts. Tightening Torque: 180 230 kg cm (14 16 Ib ft) 6. Install the cam lever and return spring. Fig. 27

1 page 1 PARKING BRAKE 14-13 5. INSTALLATION 1. Install the anchor plate assembly on the transmission rear cover. Tighten the bolts. Fig. 28 SM14-121 Tightening Torque: 1,122 1,346 kg cm (82 97 lb ft) NOTE: Make sure the grease and oil do not contact dust cover or transmission installation surface. If soiled with grease or oil be sure to clean the parts. 2. Install the flange coupling. Fig. 29 SM14-120 3. Install the spacer and O-ring to the main shaft, and secure the spacer by tightening the nut. Use the socket wrench and handle. Refer to CHAPTER 7, TRANSMISSION. Tightening Torque: 1,150 1,380 kg cm (84 99 lb ft) Fig. 30 S SM14-119 NOTE: Install the spacer S. Apply adhesive (THREE BOND No. 1215 or equivalent) to A. Fig. 31 A O-RING SM14-037 4. Install the cotter pin. Fig. 32 SM14-140

14-14 PARKING BRAKE 1 page 1 5. Install the brake drum, aligning the marks. Match the alignment marks on the flange coupling and brake drum. Fig. 33 SM14-118 6. Secure the drum with nuts. Tightening Torque: 650 870 kg cm (47 62 lb ft) Fig. 34 SM14-117 7. Install the propeller shaft, Tightening the propeller shaft yoke with flange. Tightening Torque: 650 870 kg cm (47 62 lb ft) Fig. 35 SM14-116A 8. Connect the control cable with the camblock lever. Tightening Torque: 190 260 kg cm (14 18 lb ft) Fig. 36

1 page 1 PARKING BRAKE 14-15 PARKING BRAKE CONTROL 4 3 4 1 2 5 8 9 10 8 6 7 6 1. Release rod knob 2. Compression spring 3. Parking brake lever 4. Pin 5. Parking brake switch 6. Spring retainer 7. Parking brake cable 8. Spacer 9. Pawl 10. Pawl release rod Fig. 1 SM14-233 1 2 1. Parking brake lever 2. Control cable Fig. 2 SM14-234

14-16 PARKING BRAKE 1 page 1 1. REMOVAL 1. Remove the parking brake lever. a. Disconnect the parking brake cable and parking switch harness. b. Remove four bolts which tighten parking brake lever, and remove the lever ass y. Fig. 3 SM14-168 2. DISASSEMBLY AND INSPECTION 1. Disassemble the parking brake lever. Fig. 4 Fig. 5 b b b a c a SM14-233A SM14-171A 2. Inspect the parking brake lever. a. Ratchet and Pawl Inspect the ratchet teeth and pawl tip for wear or damage. b. Pins and Bushings Check cable pin, pawl pin and their bushing for wear. Check pivot pin, brake lever and bracket for play. c. Washers Check washers for wear. 3. Inspect the control cable for sliding condition, rusting and any other damage. The cable must be free from any evidence of cut or tendency to kink. Replace defective cables, if any. Fig. 6 SM14-145 3. ASSEMBLY 1. Parking brake lever assembly. a. Apply sufficient wheel bearing grease to the ratchet teeth and both sides of part A. A Wheel bearing grease: Refer to RECOMMENDED LUBRICANTS LIST. Fig. 7 SM14-171B

1 page 1 PARKING BRAKE 14-17 b. Assemble the parking brake lever. Apply sufficient wheel bearing grease to release rod and pin of pawl, then assemble the components. Adjust the parking buzzer switch. (See Page 14-6). Wheel bearing grease: Refer to RECOMMENDED LUBRICANTS LIST. Fig. 8 SM14-233A 4. INSTALLATION 1. Install the parking brake lever. Tightening Torque: 380 500 kg cm (28 36 lb ft) Fig. 9 SM14-169 2. Connect the parking brake lever with the control cable, and coat pin with chassis grease. Chassis grease: Refer to RECOMMENDED LUBRICANTS LIST. Fig. 10 SM14-170 NOTE: Installation of the cable (When replacing with new one) Band radius of cable should be more than 200 mm (7.87 in.). The cable should not be touched with flange edge of the frame. Clip the cable with part of marked portion.

14-18 PARKING BRAKE 1 page 1 FINAL INSPECTION AND ADJUSTMENT 1. ADJUSTMENT 1. Adjustment of shoe clearance and cable. After assembling, adjust them according to item INSPECTION AND ADJUSTMENT. 2. Burnishing of lining. When replacing lining or drum of parking brake to new parts be sure to perform lapping by the following procedure. Braking force may be extremely lowered without lapping, so be sure to perform the lapping. NOTE: Apply parking brake only burnishing after replacing the lining and in an emergency when the vehicle is moving. a. Confirm that shoe clearance and cable have been correctly adjusted. b. While running the vehicle at a speed of 10 km/h (6.21 mph) in a safe place, depress the clutch pedal and apply the parking brake with about 25 kg (55 lb) pull. Repeat this 10 times. c. After operation, adjust shoe clearance and cable clearance according to item IN- SPECTION AND ADJUSTMENT. 3. Confirmation of parking brake application. After completing all brake adjustment, stop the vehicle on a safe slope or using a brake tester, confirm whether the parking brake is securely applied.