Brakes - Excessive Travel of Parking Brake Lever
XT206-03X-TYPE
DATE 10/02
MODEL
2002 MY
X-TYPE
VIN
C00294-D03127
Excessive Travel Of Parking Brake Lever - Internal Clutch Mechanism Wear - Modification Procedure
Issue:
Some 2002 MY X-TYPE vehicles within the above VIN range may experience a progressive increase in the travel of the parking brake lever.
The progressive increase in travel may be caused by a deterioration of the parking brake lever internal clutch mechanism. The angle at which the clutch engages increases over time due to initial setting of lever components, initial wear and clutch spring elongation. To rectify this concern, a clip should be installed to the clutch spring stop.
Action:
On a customer complaint basis only, follow the workshop procedure outlined below.
Workshop Procedure
1. Open hood, fit fender protectors.
2. Remove battery cover, disconnect battery.
3. Remove floor console (see Workshop Manual, JTIS CD ROM, section: 501-12, SRO 76.25.01).
Note:
Make sure the parking brake lever is in the off position.
4. Using suitable pliers, bend the clutch spring stop away from the clutch spring to obtain a 0.2 mm gap (Illustration 1). Measure gap using feeler gauges.
5. Apply parking brake lever by two notches to obtain a suitable gap between the clutch spring and stop.
6. Using suitable pliers, install new clip to the stop making sure the curved edge is facing upwards (Illustration 2).
7. Fully release the parking brake lever.
8. Mark parking brake cable and grommet (Illustration 3).
9. Apply parking brake lever one notch and measure distance traveled. (Illustration 4)
10. Check the stroke measurement according to the following table.
Stroke Verification
Manufacturing Date Stroke
Any date code other than 20 02 8.5 - 10.5 mm
With 20 02 date code 11.5 - 13.5 mm
Note:
The manufacture date of the parking brake lever can be obtained from the parking brake lever body (Illustration 5).
11. If the stroke of the cable is greater than the specified amount, bend clutch spring stop and clip slightly downwards towards the clutch spring until the correct value has been attained (Illustration 6).
12. If the stroke of the cable is less than the specified amount, bend clutch spring stop and clip slightly upwards away from the clutch spring until the correct value has been attained (Illustration 7).
13. Install floor console (see Workshop Manual, JTIS CD ROM, section: 501-12, SRO 76.25.01).
14. Connect battery, install battery cover.
15. Remove fender protectors, close hood.
Note:
When this Technical Bulletin has been completed it should not be necessary to carry out the parking brake lever resetting process again.
Parts Information
Warranty Information
Warranty claims should be submitted quoting the information found in the table. This will result in payment of the stated time and, where applicable parts/miscellaneous expense codes as listed.