Parking Brake and Actuation - P
arking Brake Shoes
Re
mo
val and Installation
Remov
a
l
W
A
RNING: BRAKE DUST, IF INHALED CAN DAMAGE YOUR
HEALTH. ALWAYS REMOVE BRAKE DUST USING A VACUUM
BRUSH. DO NOT USE A COMPRESSED-AIR LINE TO DISPERSE BRAKE DUST INTO THE ATMOSPHERE.
CAUTION: 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.
1. Ra
ise rear of vehicle and support
on stands. Refer to section
100-02.
2. Remove both rear wheels.
3. Remove both rear brake discs. Refer to operation 70.10.13.
4. Re
move front shoe retaining pin.
Align hub ac
cess hole with retaining pin.
Turn pin until
it rel
eases
from backing plate.
5. Remove adju ster assembly.
Move front shoe forwards.
Remove adju
ster assembly.
6. Re
move rear shoe retaining pin.
Al
ign hub ac
cess hole with retaining pin.
Turn pin until
it rel
eases
from backing plate.
7. Remove brake shoes from parkin g brake lever-mechanism and
remove shoes from vehicle.
8. Remove return sp rings from shoes.
Anti-Lock Control -
Lubri
cants, Fluids, Sealants and Adhesives
Torques
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
Bol
t - front wheel speed sensor
8-
10
Bolt
- rear wheel speed sensor
8-
10
Bo
lt - hydraulic control unit to bracket
8-
10
Bolt -
hydraulic control unit bracket to body
10
-14
Hub rotor nut2
70-330
Com
ponent
Nm
Bleed n
ipple - front
4-
6
Bleed n
ipple - rear
8-1
1
Hose to fr
ont caliper
10
-14
Hose banjo to rear caliper -
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
Anti-Lock Control - Anti-Lock Brake System (ABS) Module
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.
Sp
ecial Tool(s)
Brake Pedal
H
old Tool
JDS 9013
1. Disc onne
ct battery ground cable (IMPORTANT, see operation
86.15.19 for further information).
2. Position vehicle on a four-post lift.
3. Open engine compartment and fit paint work protection covers
to fenders.
4. NOTE : Th
e following three pictorial procedures must be
carried-out to minimize brake fl uid loss when disconnecting the
brake tubes.
Open Left-Hand-Front and Left-H and-Rear caliper bleed nipples.
Connect a
bleed tube and co
ntainer to the calipers.
Op
en bleed nipples.
5. Depress and hold down brake pedal u s
ing special tool.
1. Position tool between brake pedal and seat frame.
2. Turn the tool wheel unti l the brake pedal is held
60mm down from its released position.
6. Tighten bleed nipples to:
Front caliper blee d nipple 4-6 Nm.
Rear
caliper bleed nip
ple 8-11 Nm.
Anti-Lock Control - Hydraulic Contro
l Unit (HCU)
Re
moval and Installation
Remov
al
• C
AUTIONS:
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.
S
pecial Tool(s)
Brake Pedal
Hold Tool
JDS 9013
1. Disc
onnect battery ground cable (IMPORTANT, see operation
86.15.19 for further information).
2. Position vehicle on a four-post lift.
3. Open engine compartment and fit paint work protection covers
to fenders.
4. NOTE
: The following three pictorial procedures must be
carried-out to minimize brake fl uid loss when disconnecting the
brake tubes.
Open Left-Hand-Front and Left-H and-Rear caliper bleed nipples.
Connect
a bleed tube and co
ntainer to the calipers.
O
pen bleed nipples.
5. Depress and hold down brake pedal u
sing special tool.
1. Position tool between brake pedal and seat frame.
2. Turn the tool wheel unti l the brake pedal is held
60mm down from its released position.
6. Tighten bleed nipples to:
Front caliper blee d nipple 4-6
Nm.
Rear
caliper bleed nipple 8-11 Nm.
Anti-Lock Control - Wheel Speed Se
nsor Ring
Re
mo
val and Installation
Remov
a
l
CAUTI
O
N: 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.
S p
ecial Tool(s)
Hub Holdin
g Tool
2
04-195 (JD 227)
ABS Rotor Nut Socket
2
06-
066A
1.
Op
en engine compartment and
fit paintwork protectors to
fenders.
2. Raise front of vehicle and support on stands. Refer to section
100-02.
3. Remove front wheel. Re fer to section 204-04.
4. Remove front brake disc. Refer to operation 70.10.12.
5. Remove vertical link and hub assembly. Refer to operation
60.25.38.90.
6. Re
move brake-disc shield from vertical link.
1. Remove screws.
2. Remove disc shield.
7. Using special tool, secure vertical link and hub assembly in a
vice.
Secure special tool
in a vice.
Posit
i
on hub in tool.
Fit and
tighten wheel nuts.
Fit sp
ring clip into the hub retaining holes and, if aligned,
into the castellated slots of the rotor nut.
If t he
castellated slots of the rotor nut are not aligned it
will be necessary to tighten the rotor nut further until the
spring clip engages the slots.
3. Remove vertical link and hub assembly from special tool.
4. Fi
t disc shield to vertical link.
1. Position disc shield.
2. Fit and tighten bolts.
5. Fit vertical link and hub assembly to vehicle. Refer to operation
60.25.38.90.
6. Fit brake disc. Refer to operation 70.10.12.
7. Fit wheel. Refer to section 204-04.
8. Remove stands an d lower vehicle.
Steering System - General Inform
ation - Steering System
D
iagnosis and Testing
I
nspection and Verification
1.
1. Verify t
he customer concern by driving the vehicle.
2. 2. Visually inspect for obvious signs of mechanical or electrical damage.
Mec
hanical Inspection Chart
Electrical Inspection Chart
Mechanical Checks
Incorrect
tire pressure, loose whee
l nuts, incorrect wheel alignment
Loose ti
e-rods
Loose dam
per and spring assemblies or ball joint
Loose s
teering column shaft universal joints
Loose pinc
h bolts on steering column shaft
Loose steeri
ng gear assembly
Check f
or external damage to the steering gear.
- Damaged tie-rods
-
CAUTION: If a steering gear assemb ly is returned under warranty with leaking seals, but there is also
damage to the steering gear boot/boots the steering gear warranty will be invalid. This is due to the steering
gear seals being damaged due to fore ign materials entering the steering gear boot and damaging the steering
gear seals thereafter.
Damaged steering gear boot
Damaged accessory driv
e belt
Bin
ding or misaligned steering co
lumn, pump or steering gear
Incorrect fluid
level
Hose leaks o
r line restrictions
Hose fou
ling bodywork
El
ectrical Checks/Tests
Make sure all
connectors are in plac
e (steering gear Servotronic solenoid and steering control module (SCM) - if
applicable)
Make su
re all the fuses are in place and not blown
D
ISCONNECT the steering gear transducer
and the steering should become heavy
TEST e
lectrical values:
- Power Supply to the SCM = 12 Volts
- Steering gear transducer resist ance 7.0 to 7.5 Ohms is normal
(
limits: less than 5 Ohms and greater than 9 Ohms would
be declared unacceptable)
- Steeri
ng gear transducer voltage = 6 Volts
- Steering gear transducer cu rrent = 840 mA at 0 mph reducing to 0 mA at maximum speed
Function
al
Fl
uid
leakage
O
verfilled system.
CORRECT the
fluid leve
l as necessary.
Compon
ent leak.
•
NOTE: Record the position of the le
ak and some indication of the rate
of the leak on the Warra nty Return Record Sheet.
LOCATE
the suspect component or CHECK hose connections and
repair as necessary.
Damaged fluid cap. INST
ALL a new fluid cap.
Loose or damaged h
ose
fittings.
TI
GHTEN or INSTALL a new hose as necessary.
Leakage at
power
steering pump.
INST
ALL a new power steering
pump as necessary. For
additional information,
REFER to Section 211
-0
2 Power Steering
.
Fl
uid
leakage
Leakage
at steering hose
to steering gear connection.
CHECK
steering hose to
steering gear conn ection for leakage.
CHECK and TIGHTEN the steeri ng hose to steering gear
connection retaining bolt s/bolts as necessary.
Power steeri
ng fluid
leakage at O-ring seals.
CHECK
the power steering system fo
r signs of steering fluid loss
from O-ring seals.
INST
ALL new O-ring seals as necessary.
BLEE
D the power steering system.
For additional information,
REF
ER to Section 211
-0
0 Steering System
- Ge
neral
Informati
on
.
Power steeri
ng fluid
leakage from transfer pipes.
CHECK
the power steering system fo
r signs of steering fluid loss
from the transfer pipes.
CHECK
and TIGHTEN the transfer pipes if required, INSTALL new
transfer pipes as necessary.
BLEE
D the power steering system.
For additional information,
REF
ER to Section 211
-0
0 Steering System
- Ge
neral
Informati
on
.
Power steeri
ng fluid
leakage from the steering
gear.
CHECK
the power steering gear for signs of fluid loss.
INST
ALL a new steering gear as
necessary. For additional
information,
REFER to Section 211
-0
2 Power Steering
.
Power steeri
ng fluid
leakage from steering gear boot.
CHECK
the power steering gear for signs of fluid loss.
INST
ALL a new steering gear as
necessary. For additional
information,
REFER to Section 211
-0
2 Power Steering
.
Cond
ition
Possib
le Sources
Acti
on
F
ree play at steering wheel
Exce
ss play in the steering
linkage.
CHECK
the steering linkage for excess play.
For additional information, REFER to the
Steering Linkage Inspection and Backlash (Freeplay) Check in this section.
S
teering wheel loose.
CHECK
and TIGHTEN the steering wheel
retaining bolt/bolts as necessary. For additional information,
REFER to Section 211
-0
4 Steering Column
.
Lower steeri
ng column
pinch bolt loose.
CHECK
and TIGHTEN the lower steering
column pinch bolts as necessary. For additional information,
REFER to Section 211
-0
4 Steering Column
.
Exce
ssive wear in lower
steering column.
CHECK
for lower steering column for wear in
the universal joints. If wear is present,
INSTALL a new lower steering column as necessary.
W
ear in suspension joints.
CAU
TION: DO NOT attempt to adjust the
steering gear yoke. Failure to follow this instruction
will result in the steering gear warranty to become
invalid.
CHECK
for excess wear in the front
suspension joints. For additional information,
REFER to Section 204
-00
Suspension
Sy
stem
- General
Information
.