Brakes - Park Brake Pedal/Cable Replacement Procedure
NO: 55-03DATE: 10-31-2003
MODEL:
XC90
M. YEAR:
2003 - 2004
CHASSIS:
0000737-0052297
SUBJECT:
Parking Brake Pedal and Primary Cable Replacement
REFERENCE:
VADIS, Special Tool Bulletin 142
DESCRIPTION:
Should it be necessary to replace the parking brake pedal assembly or the primary parking brake cable on an XC90 produced prior to chassis # 052298, it will be necessary to replace both the pedal assembly and the primary parking brake cable (kit PN 274519). The parking brake shoes will also need to be inspected.
If the parking brake pedal mechanism or the primary parking brake cable should need replacement on a vehicle that is produced after chassis # 052297, only the faulty component should be replaced.
SERVICE:
Replacing the Parking brake pedal and the primary parking brake cable.
Preparation 1
Remove the parking brake pedal assembly. As per VADIS.
Remove the center console. As per VADIS.
Removing the primary parking brake cable 2
Remove:
- the rear cables from the primary cable yoke
- the cable from the bracket.
Remove the lower screw for the accelerator pedal 3
(APM) and loosen the two upper screws.
Lift the accelerator pedal (APM). 4
Pull the mechanical cable downwards so that it comes out from the behind the mounting plate for the accelerator pedal (APM). Pull the primary brake cable backward out through the tunnel (console area).
Operation of the mechanical adjuster. 5
To remove slack from the cable or tighten the parking brake, part A and B will be pulled apart using special tool # 9512947, as A and B are pulled apart a clicking noise will be heard, after each click the cable will be locked in that position.
In order to release the cable or loosen the parking brake.
A. Remove clip D
B. Turn part B as illustrated in the direction of part C, continue turning until Part A is released and can be slid into part B.
C. Resetting the cable, turn part B in the opposite direction and reinstall clip D.
Installing the primary cable 6
Adjust the cable to the fully released position, so that the inner cable is at its longest length.
Pull the primary cable into the center of the tunnel above the insulation, and route the cable to the pedal mechanism.
Press the primary cable into place in the pedal mechanism.
Note!
The wide edge of spacer (A) must point to the left side.
Apply low-temperature grease, P/N 1161427-8, to the end piece of the mechanical cable (B).
Connect the end of the primary cable to the cable pulley in the pedal mechanism.
Install 7
- the rear mechanical cables on the primary cable.
- the cable sleeve clips on the bracket.
Note
Do not reinstall the balance spring when using a mechanically adjusted cable.
Installing the parking brake pedal 8
Install:
- the release cable (3) for the pedal.
- the electrical wiring (2) for the switch
- the 3 parking brake pedal screws (1)
Install: 9
- the accelerator pedal (APM)
- the CEM
- the OBDII bracket
Checking the Parking brake shoes 10
Inspect the parking brake shoes. If the flat spot is not visible or if the shoes are worn out, install new parking brake shoes As per VADIS (kit PN 274504). Always use new caliper bolts whenever the calipers are removed.
Note!
It will be necessary to follow the wear in procedure in step 12 if the parking brake shoes have been replaced.
Adjusting the parking brake 11
Depress the brake pedal to the first notch.
Press out the adjustment using special tool # 9512947.
Test the parking brake.
Full effect should be obtained between four and seven pedal clicks.
Note!
The parking brakes will have full effect between four and seven clicks, however the total pedal travel may have ten clicks depending on how hard the pedal is depressed.
Fully apply the parking brake, Wait 10 minutes, and readjust if necessary. (This step will help ensure that the final adjustment will be correct).
Wearing in the brake shoes 12
Wear in the parking brake shoes. Depress the parking brake pedal to the third notch until light drag is applied. Then drive at 12 mph for 40 seconds.
Readjust the parking brake as required.
Reinstall the center console. 13
Note!
After the road test ensure that the parking brake isn't over adjusted causing the rear wheels to drag.
Warranty Information