1993 CHEVROLET PLYMOUTH ACCLAIM Service Manual

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Page 209 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual FIG. 3 PARKING BRAKE CABLE ROUTING AC AND AY-BODY
Ä BRAKES 5 - 59

Page 210 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual FIG. 4 PARKING BRAKE CABLE ROUTING AG AND AJ BODY
5 - 60 BRAKES Ä

Page 211 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual WARNING: THE SELF ADJUSTING FEATURE OF THIS
PARKING BRAKE LEVER ASSEMBLY CONTAINS A
CLOCK SPRING LOADED TO APPROXIMATELY 30
POUNDS. CARE MUST BE TAKEN TO PREVENT EX-
CESSIVE JARRING OF THE ASSEMBLY.

WARNING: THE SELF ADJUSTING FEATURE OF THIS
PARKING BRAKE LEVER ASSEMBLY CONTAINS A
CLOCK SPRING LOADED TO APPROXIMATELY 30
POUNDS. CARE MUST BE TAKEN TO PREVENT EX-
CESSIVE JARRING OF THE ASSEMBLY. DO NOT
RELEASE THE SELF ADJUSTER LOCKOUT DEVICE
BEFORE INSTALLING CABLES INTO THE EQUAL-
IZER. KEEP HANDS OUT OF SELF ADJUSTER SEC-
TOR AND PAWL AREA. FAILURE TO OBSERVE CAU-
TION IN HANDLING THIS MECHANISM COULD LEAD
TO SERIOUS INJURY.
When repairs to the hand lever assembly or cable
system are required the self adjuster must be reloaded
and locked out.
SELF ADJUSTING PROCEDURES (AG & AJ BODY)
TO RELOAD SELF ADJUSTER
(1) Remove ash receiver or courtesy light from rear
of center console to gain access to self adjuster. Also,
remove carpet from sides of console. (2) Pull on equalizer/output cable to wind up sprin-
g(requires greater than 30 pounds effort). Continue
until self adjuster lockout pawl is positioned about
midway on the self adjuster sector (Fig. 6). Rotate
lockout pawl into self adjuster sector by turning allen
screw clockwise. Rotating lockout device requires
very little effort. Do not force or failure of lock-
out device will occur. (3) When repairs are complete, adjust rear brakes
before adjusting parking brake. On drum-in-hat type of
rear disc brake adjust shoe diameter to 171.5 mm (6.75
inch).
ADJUST PARKING BRAKE (AG & AJ BODY)
Be sure that the cables are properly assembled to the
equalizer bracket prior to cable adjustment. (1) Insert a 7/32 inch allen wrench into hex socket
and turn counter-clockwise through approximately 15É
of rotation (Fig. 4). In turning lockout device, self
adjuster release is a loud snapping noise followed by
reaching a more felt than heard detent. Very light
effort is required to seat lockout arm into detent.
Follow through to the detent is important in prevent-
ing the lockout rod from rattling. Note: The parking brake handle can be in any
position when releasing self adjuster. (2) Cycle lever to position cables. Rear wheels should
rotate freely without dragging.
REAR PARKING BRAKE CABLE REMOVAL (AA, AC,
AP, AY BODY)
The rear brake cables are attached to rear connec-
tors. Should it become necessary to remove either parking
brake cable for installation of a new cable, proceed as
follows: With vehicle jacked up on a suitable hoist, remove
wheel and tire assembly (Fig. 6). Back off cable adjusting nut to provide slack and
disconnect rear brake cable from connector.
DRUM BRAKES
(1) Disconnect park brake cable from park brake
lever in rear wheel brakes. (2) Using an aircraft type hose clamp compress re-
tainers on end of cable housing and start cable out of
retaining hole in the support plate. Remove clamp
when retainers are free of the mounting hole in the
support plate, (Fig. 6).
(3) Remove clip from brake cable at support
bracket and pull cable away from trailing arm as-
sembly (Figs. 3 and 4).
DISC BRAKES
(1) Remove disc brake caliper from adapter, and
brake disc (rotor) from rear hub.
Fig. 5 Self Adjusting Parking Brake Lever Assembly
Fig. 6 Removing Brake Cable from Support Plate
Ä BRAKES 5 - 61

Page 212 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual (2) Disconnect parking brake cable from brake
shoe lever. (3) Using an aircraft type hose clamp compress re-
tainers on end of cable housing and start cable out of
retaining hole in the adapter. Remo

(2) Disconnect parking brake cable from brake
shoe lever. (3) Using an aircraft type hose clamp compress re-
tainers on end of cable housing and start cable out of
retaining hole in the adapter. Remove clamp when
retainers are free of mounting hole in the adapter
(Fig. 6). (4) Remove clip from parking brake cable at
hanger bracket and pull cable away from trailing
arm.
REAR PARKING BRAKE CABLE INSTALLATION
DRUM BRAKES (AA, AC, AP, AY BODY)
(1) Route parking brake cable assembly through
trailing arm and hanger bracket. (2) Install parking brake cable retaining clip.
(3) Install parking brake cable into rear brake sup-
port plate. Be sure all retainers are expanded around
mounting hole in brake support plate, and then con-
nect parking brake cable end to brake shoe lever. (4) Insert forward end of parking brake cable into
connector. (5) Install brake drum, and wheel and tire assem-
bly.
DRUM BRAKES (AG & AJ BODY)
(1) Route each parking brake cable assembly
through trailing arm and mounting bracket. (2) Install parking brake cable retaining clip.
(3) Install parking brake cable into rear brake sup-
port plate. Be sure the retainers are expanded
around mounting hole in the brake support plate and
connect parking brake cable end to brake shoe lever. (4) Insert forward end of parking brake cable into
floor pan of vehicle. Then connector park brake cable
to equalizer at park brake hand lever. (5) Install brake drum, and wheel and tire assem-
bly.
DISC BRAKES (AA, AC, AP, AY BODY)
(1) Route parking brake cable assembly through
trailing arm and parking brake cable hanger
bracket. (2) Install parking brake cable to hanger bracket
retaining clip. (3) Install parking brake cable into rear brake
adapter. Be sure all cable retainers on parking brake
cable are expanded around mounting hole in adapter
and connect cable end to brake shoe lever. (4) Insert forward end of cable into connector.
(5) Adjust parking brake shoe diameter to 171 mm
(6.75 inch). (6) Install rear braking disc, caliper assembly and
wheel and tire assembly.
DISC BRAKES (AG & AJ BODY)
(1) Route each individual parking brake cable as-
sembly through trailing arm and parking brake ca-
ble mounting bracket. (2) Install parking brake cable to mounting
bracket retaining clip. (3) Install parking brake cable into rear disc brake
adapter. Be sure all cable retainers on parking brake
cable are expanded around mounting hole in adapter,
and then connect cable end to brake shoe lever. (4) Insert forward end of parking brake cable into
floor pan of vehicle. Then connector park brake cable
to equalizer at park brake hand lever. (5) Adjust parking brake shoe diameter to 171 mm
(6.75 inch). (6) Install rear braking disc, caliper assembly and
wheel and tire assembly.
REMOVING PARKING BRAKE FRONT CABLE (AA,
AC, AP, AY BODY)
(1) Loosen parking brake cable adjusting nut un-
der car. Disengage front cable from intermediate ca-
ble connector (Fig. 2). (2) Remove park brake cable retaining clip from
floor pan of vehicle. (3) Lift floor mat for access to floor pan.
(4) Remove floor pan seal.
(5) Pull parking brake cable strand end forward
and disconnect from foot lever clevis. Separate park-
ing brake cable from parking brake foot lever and
bracket on body rail. (6) Pull parking brake cable assembly through
hole in floor pan and up into vehicle.
INSTALLING PARKING BRAKE FRONT CABLE (AA,
AC, AP AY Body)
(1) Insert parking brake cable housing retainers
into hole in rail bracket and parking brake foot lever
assembly (Fig. 2). (2) Feed parking brake cable end through holes in
floor pan and rail bracket, from the interior of the
vehicle. (3) Install floor pan seal.
(4) Engage parking brake cable strand end in foot
lever clevis. Seat cable ends in parking brake assem-
bly and parking brake cable rail bracket. (5) Replace floor mat.
(6) Attach park brake cable retaining clip to floor
pan of vehicle. (7) Engage rear parking brake cable end to inter-
mediate cable connector. (8) Adjust service and parking brakes.
5 - 62 BRAKES Ä

Page 213 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual PARKING BRAKE HAND LEVER ASSEMBLY
REMOVAL AND INSTALLATION
REMOVAL (AG AND AJ BODY)
Remove ash receiver or courtesy light from rear of
console. Remove carpet from sides of console. Remove
parking br

Page 214 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual INSTALLING PARKING BRAKE SHOES
(1) Install rear parking brake shoe and holddown
clip (Fig. 6). (2) Install lower parking brake, shoe to shoe re-
turn spring (Fig. 7). (3) Pull forward parking brake

Page 215 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual (16) Install wheel and tire assemblies. (17) Tighten wheel stud nuts to 129 N Im (95 ft-
.lbs.).
Fig. 7 Installing Lower Spring
Fig. 8 Installing Upper Spring
Fig. 9 Installing Adjuster Assembly
Fig.

Page 216 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual MASTER CYLINDER INDEX
page page
Brake Fluid Level Sensor .................. 66
General Information ....................... 66 Master Cylinder Service Procedures
.......... 67
Testing the Master

MASTER CYLINDER INDEX
page page
Brake Fluid Level Sensor .................. 66
General Information ....................... 66 Master Cylinder Service Procedures
.......... 67
Testing the Master Cylinder ................. 66
GENERAL INFORMATION
The tandem master cylinder (Fig. 1) has a glass re-
inforced nylon reservoir and an anodized aluminum
body. Do not hone the bore of the cylinder, as this will
remove the anodized surface. The reservoir is indexed to prevent installation in
the wrong direction (Fig. 2). The cap diaphragms are
slit to allow atmospheric pressure to equalize on both
sides of the diaphragm. The primary and secondary outlet tubes from the
master cylinder are connected to the valve mounted
under the master cylinder. The front part of this
block connects to the secondary outlet tube and sup-
plies the right rear and left front brakes. The rear
portion of the block connects to the primary outlet
tube and supplies the right front and left rear
brakes.
BRAKE FLUID LEVEL SENSOR
The Brake Fluid Level sensor is found only in the
AJ body vehicles with the visual electronic message
center. The purpose of the sensor is to provide the
driver with an early warning message that brake
fluid in master cylinder reservoir has dropped to a
below normal. As the fluid drops below the design level the sensor
closes the warning message circuit. Approximately
15 seconds later the message BRAKE FLUID LOW
appears on the instrument panel. At this time the master cylinder reservoir should be checked and filled
to the bottom of the rings with DOT 3 brake fluid. To check the operation of the Brake Fluid Level
sensor, with ignition on and wiring still attache-
d,remove sensor from master cylinder and hold in
upright position. Within 30 seconds the instrument
panel message BRAKE FLUID LOW should appear.
Next invert the sensor. The instrument panel message
should turn off immediately. If the above sequence
occurs the sensor is operating properly. If the message
does not appear remove the wiring from the sensor and
using a jumper wire connect both sides of the plug. The
instrumental panel message BRAKE FLUID LOW
should appear within 30 seconds. If the message does
not appear a problem exists in the wiring or instru-
mentation. If the message does appear the sensor is
faulty and must be replaced. The Brake Fluid Level
sensor is not a repairable item (Fig. 2).
TESTING THE MASTER CYLINDER
Be sure master cylinder vents at both ports.
Apply pedal lightly with engine running and look for
fluid squirting or swirling into reservoirs. In this master cylinder, a special baffle reduces the
amount of fluid entering the secondary reservoir only a
small disturbance may be seen.
Fig. 1 Aluminum Master Cylinder (Cutaway View)
Fig. 2 Brake Fluid Level Sensor
5 - 66 BRAKES Ä

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