Page 401 of 2490
I
nstallation
1
. Remove upper return spring.
2. Remove lower return spring.
9. Remove brake dust and clean components, see WARNING
above.
10. Repeat procedure to remove pa rking brake shoes on opposite
side of vehicle.
1. I
nstall brake shoes to vehicle.
Install brake shoes to parkin
g brake lever-me
chanism in
the arrangement shown.
2. N
OTE: Make sure retaining pin is seated correctly in backing
plate.
Install rear shoe retaining pin.
Align hu
b access hole.
Inst
all retaining pin.
3. Inst
all adjuster assembly.
Lubricate adjuster
mechanism
with appropriate grease.
Move
front shoe forwards.
Inst
all adjuster assembly.
4. NOTE: Make sure retaining pin is seated correctly in backing
Page 402 of 2490
plate.
Install front
shoe
retaining pin.
Align hu
b acc
ess hole.
Inst
al
l retaining pin.
5. Make sure brake shoes are seat ed correctly in adjuster and
lever mechanism.
6. Repeat procedure to install parking brake shoes on opposite
side of vehicle.
7. Install both rear br ake discs. Refer to operation 70.10.13.
8. Set parking brake. Refer to operation 70.35.37.
9. Fit rear wheels. See section 204-04.
10. Remove stands an d lower vehicle.
Page 403 of 2490
Parking Brake and Ac
tuat
ion - Parking Brake Warn ing Indicator Switch
Re
moval and Installation
Remov
al
Installation
1. R
emove driver seat for access. Refer to 76.70.01.
2. Raise hand lever fully.
3. Remove trim from hand lever. Refer to operation 76.13.63.
4. R
emove screws securing
switch to hand lever.
5. Di
sconnect electrical connector from switch.
1. Di
sconnect electrical connector from switch.
2. Install switch to hand lever.
Install and tigh
ten
screws to 3 Nm.
Page 404 of 2490
3.
Inst
all trim to hand lever.
Refer to operation 76.13.63.
4. Lower hand lever, checking for freedom of movement.
5. Fit driver seat. Refer to 76.70.01.
Page 405 of 2490

Hydraulic B
rake Actuation -
Lubri
cants, Fluids, Sealants and Adhesives
Torques
Torques - Brembo Brakes
Brake Tube, Hoses and Bracket Torques
CAUTI
ON: Replacement of
nuts and bolts: Various thread-locking devices are used on nuts and bolts throughout the
vehicle. These devices restrict the number of times a nut or bolt can be used. See section 100-00 for information.
UnitS
pecification
Brake flu
id
ITT Supe
r Dot 4
Com
ponent
Nm
N
ut - master cylinder to brake booster
21
-29
Nu
t - brake pedal pivot-pin to pedal housing
17
-23
Nu
t - brake switch to pedal housing
3
Nu
t - pedal housing to body
15
-20
Nu
t - brake booster to pedal housing
22
-28
Com
ponent
Nm
Bleed n
ipple
12
-16
U
nion bolt - brake hose to caliper
22
-26
Com
ponent
Nm
Bleed n
ipple - front
4-
6
Bleed n
ipple - rear
8-1
1
Hose to fr
ont caliper
10
-14
U
nion to rear caliper - union bolt
30
-40
M1
0 hose locknut
15
-20
M10
brake tube female-nut
13
-17
M10
brake tube male-nut
13
-17
M12
brake tube male-nut
15
-20
M18
brake tube male-nut
22
-28
Brake tube clip retention
-bracket to body
4-
6
Page 406 of 2490
Hydraulic Br
ake Actuation -
Hydraulic Brake Actuation
Description and Operation
The hydraulic brake system is split in to two independent circuits: the primary ci rcuit operates the front brakes and the
secondary circuit operates the re ar brakes. This type of system prevents comple te brake failure in the event of a brake tube
fracture.
The hydraulic brake system consists of the following components:
Ite
m
Descr
iption
1Pedal Housi
ng / Booster - refer to 206-07
2Vacu
um Hose - refer to 206-07
3Mast
er Cyl
inder / Reservoir
4Primary Brake Circu
i
t
5Secon
dary Brake Circuit
6Hydrauli c
Pump / Motor Unit - refer to 206-09
7ABS/Traction
Control Control Modu
le (ABS/TCCM) - refer to 206-09
8Hydraulic Cont
rol Unit (HCU) - refer to 206-09
6/
7/
8
Br
ak
e Control Modulator
9Brake
Di
sc - refer to 206-03 or 206-04
10Brake
Cali
per - refer to 206-03 or 206-04
11W
h
eel Speed Sensor - refer to 206-09
12ABS Warning Lamp -
refer to 206
-09
13Brake F
l
uid Level Warning-Lamp
Page 407 of 2490

The t
andem master cylinder contains two in
dependent pistons, fluid pressure to each brake circuit is controlled by its own
individual piston. Brake fluid is supplied to the master cylinder by the reservoir, which is divided into two sections to preve nt
total fluid loss should one of the circuits fail. A port situated at the bottom of each section of the reservoir supplies the f luid
to each piston.
The fluid reservoir has a fluid-le vel indicator switch installed, which operates when the fluid level is low, causing the brake
fluid level warning-lamp to illuminate.
Bra
ke Caliper
The brake
calipers are of the single piston
type. The caliper carrier, which is secured to the vertical link by two bolts, carr ies
the single-piston caliper housing. The cali per housing is secured to the caliper carrier by two guide-pins and an anti-rattle
spring. When the brakes are applied, the caliper-housing piston pushes the brake pad in front of it, to wards the brake disc.
This movement forces the calipe r housing to move along the guid e-pins, in the opposite direction of the piston, to apply the
second brake pad.
Br
embo Brake Caliper
The four
cylinder brake caliper is rigidly attached to the vert
ical link via an anchor bracket. The caliper is a split assembly
with each side of the caliper, housing two pistons. The two-pairs of opposed pistons act direct ly on the brake pads mounted
one each side of the disc.
Mast
er Cylinder and Reservoir
Page 408 of 2490

Hydraulic Br
ake Actuation
- Brake Fluid Reservoir
Remo
val and Installation
Remov
a
l
• C
A
UTIONS:
Replacement of nuts and bolts: Various thread-locking de vices are used on nuts and bolts throughout the vehicle.
These devices restrict the number of times a nut or bolt can be used. See section 100-00 for information.
Remove brake fluid spilla ge immediately from paint work, with clean water.
1. Position vehicl
e on a four-post lift.
2. Open engine compartment and fit paint work protection covers
to fenders.
3. Disconnect battery ground cable (IMPORTANT, see operation
86.15.19 for further information).
4. Remove engine compartment rear cover. Refer to operation
76.11.35.
5. Remove pedal housing, brake booster and master cylinder
assembly. Refer to operation 70.35.39.
6. Remove reservoir filler cap and empty residual brake fluid into
a container. Refit cap.
7. Re
move fluid reservoir from master cylinder.
R
e
move locating pin.
Pull reservoir
from master cylinder.
8. Install plugs into f
luid reservoir ports.
9. Remove and discard seal s from master cylinder.