Page 465 of 3229
Publi s hed: 11-May-2011
Parking Brake and Actuation - Parking Brake Shoes
Removal and Inst all ati on
Removal
• NOTE: If the parki ng brake s hoes or t he brake di scs have been removed for access to ot her components t hen DO NOTcarry out t he bedding i n procedure.
1. W ARNING: Do not work on or under a vehi cle s upported onl yby a jack. Al ways support t he vehi cl e on s afet y s tands .
Rais e and s upport t he vehi cl e.
1.
Remove t he wheel s and t ires .
Refer t o: W heel and Ti re (204-04 W heel s and Tires, Removal andInst all at ion).
2.
Remove both rear brake dis cs.
Refer t o: Brake Dis c (206-04 Rear Dis c Brake, Removal andInst all at ion).
3.
4.
5.
Page 466 of 3229

6.
7.
Repeat t he above procedure for t he other s ide.8.
Installation
1. W ARNING: Do not use compress ed air t o clean brakecomponent s. Dus t from fricti on mat erial s can be harmful i f inhaled.
Clean t he backi ng plat e and appl y greas e t o t he brake s hoecont acts .
1.
Clean t he adjus t er and s et it to i ts mini mum ext ens ion.2.
3. CAUTION: Make s ure the brake shoe s pri ng is not overs tretched.
Inst all t he s econdary brake s hoe.Connect t he parking brake cable.Connect t he parking brake cable ret ai ning s pri ng t o the brakes hoe lever, making sure t he s pring i s not twis ted.Inst all t he hol d-down s pri ng and ret aining pi n.
3.
4. W ARNING: Make sure t he ret urn s pri ng and t he adjus ters pri ng are correct ly ins tal led t o t he pri mary s hoe.
CAUTION: Make s ure the brake shoe s pring i s not overs tretched.
Inst all t he pri mary brake shoe.Inst all t he s preader plat e and t he s pring.Inst all t he ret urn s pri ng.Inst all t he hol d-down s pri ng and ret aining pi n.
4.
Page 467 of 3229
5. CAUTION: Make s ure the brake shoe s pri ng is not overs tretched.
Inst all t he brake s hoe adjus ter.
5.
Repeat t he above procedure for t he other s ide.6.
Inst all both rear brake dis cs.
Refer t o: Brake Dis c (206-04 Rear Dis c Brake, Removal andInst all at ion).
7.
Inst all t he wheel s and t ires .
Refer t o: W heel and Ti re (204-04 W heel s and Tires, Removal andInst all at ion).
8.
If neces sary, carry out t he parking brake s hoe bedding-i n procedure.
Refer t o: Parking Brake Shoes Bedding-In (206-05 Parking Brake andActuat ion, General Procedures ).
9.
Page 468 of 3229
Publi s hed: 11-May-2011
Hydraulic Brake Actuation -
General SpecificationItemSpecification
Master cylinder bore diameter:
Pri mary27 mmSecondary27 mm
St roke36 mm
Torque Specifications
DescriptionNmlb-ft
Brake boos ter t o brake pedal bracket nuts2216Brake mast er cyl inder nut s2619
Brake pedal bracket nuts2518
Brake pi pe unions1511Flui d res ervoir t o mas t er cyli nder64
Page 469 of 3229
Publi s hed: 11-May-2011
Hydraulic Brake Actuation - Hydraulic Brake Actuation
Des cript ion and Operat ion
COMPONENT LOCATION
• NOTE: Left -Hand Drive (LHD) shown; Right -Hand Drive (RHD) s imi lar.
ItemPart NumberDescription1-Brake boos ter
2-Brake pedal
Page 470 of 3229

3-St opl amp s wit ch
4-Hydrauli c pipes
5-Integrat ed Hydrauli c Cont rol Unit (HCU) and Anti -l ock Brake Sys t em (ABS) modul e6-Brake mast er cyl inder and flui d res ervoir
OVERVIEW
The hydraulic brake s ys t em i s a diagonally spl it dual ci rcuit s yst em and cons is ts of the brake pedal, brake mast er cyl inder,HCU and t he hydrauli c pipes and hoses . The s ys t em al so features a non-acti ve brake boost er.For addit ional informat ion, refer t o: Brake Boos ter (206-07 Power Brake Act uati on, Des cript ion and Operat ion).
The preformed rigi d brake pipes di st ri but e press ure from t he mas ter cyli nder t o t he 4 brake cali pers , vi a t he int egratedHCU and ABS modul e. Fl exi ble hos es connect the rigid brake pipes t o t he front and rear cal ipers .
BRAKE PEDAL
ItemPart NumberDescription
1-St oplamp swi tchThe brake pedal i s mounted in a bracket t hat is at tached to the rear si de of the engine bul khead. The pedal as sembl y isdifferent for LHD and RHD vehicles , and is connect ed to the brake boos t er pus h rod wit h a cl evi s pin.
The s toplamp s wit ch is mount ed on t he brake pedal bracket and wil l ill uminat e the vehicl e s toplamps when the brakepedal i s pres s ed. The s t opl amp s wit ch is al s o used as an input to the speed cont rol s ys tem, and wi ll cancel the currents peed set ti ng when t he brake pedal i s pres s ed. For addi ti onal i nformat ion, refer to:
Speed Cont rol - 3.2L (310-03 Speed Cont rol - 3.2L, Des cript ion and Operat ion),Speed Cont rol - 2.2L Di esel (310-03 Speed Cont rol - 2.2L Di esel , Descri pti on and Operat ion).
BRAKE MASTER CYLINDER AND FLUID RESERVOIR
Page 471 of 3229

ItemPart NumberDescription
1-Brake fluid res ervoir cap2-Brake fluid level s wi tch
3-Brake fluid res ervoir
4-Secondary circui t inlet port5-Primary circui t inl et port
6-Brake mas ter cyli nder
7-Screw8-Primary circui t outl et port
9-Secondary circui t out let port
The brake mas t er cyli nder i s att ached t o t he front of the brake boos ter, on t he driver's s ide of t he engine compart ment.The brake mas t er cyli nder i s a t andem desi gn that s uppl ies press ure to 2 independent (primary and s econdary) hydrauliccircuit s . Each ci rcuit is connect ed between t he cali pers of diagonal ly opposi ng front and rear wheel s t o provide a fai l safebrake s yst em.
A reservoi r is mount ed on t op of the mast er cyl inder and retai ns suffi ci ent vol ume of hydraul ic flui d to allow for normals ys t em us e, and to compens ate for the replenis hment of the s ys tem as the brake li nings wear. The res ervoi r is i nt ernall ydivided t o provi de an independent s uppl y of fl ui d t o each brake circui t, and prevents a s ingle flui d leak from dis abling bot hpri mary and secondary brake circui ts . If a fai lure occurs i n one brake hydrauli c circui t the remaining ci rcuit wi ll s ti ll operat eeffect ively, alt hough brake pedal t ravel and vehicle braking dis t ances wi ll increas e.
On vehicles wi th manual t rans mis s ion, t he brake fluid res ervoir als o s upplies hydrauli c fluid for operati on of the cl ut chas sembl y.
Brake Fluid Level Switch
Page 472 of 3229
ItemPart NumberDescription
1-Contact carri er2-Contact
3-Float
The res ervoir i ncorporates a brake fl uid l evel s wit ch t hat i s hardwired t o t he Cent ral Junct ion Box (CJB). W hen t he res ervoirfl uid fall s to a predet ermi ned low l evel , the s wi tch contacts cl os e and provi de a s ignal feed back t o the CJB. The CJB t henbroadcas t s a mes s age on t he medium speed Controll er Area Network (CAN) bus t o t he i ns t rument clus ter t hat i n t urnil lumi nat es t he brake fluid warning i ndi cat or lamp.For addit ional informat ion, refer t o: Ins t rument Clus ter (413-01 Inst rument Cl us t er, Des cript ion and Operat ion).
HYDRAULIC CONTROL UNIT