206-05-1 Parking Brake and Actuation 206-05-1 SECTION : 206-05 Parking Brake and Actuation VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS PAGE SPECIFICATIONS Specifications 206.05-2 DESCRIPTION AND OPERATION Parking Brake — Sedan ...rsnnnnnnnnn i 7 sense B08-05-3 Parking Brake — UteWagon vo. fosnnnnnsnn see 208-05-3 GENERAL PROCEDURES Parking Brake Cable Adjustment 206-05-4 Parking Brake Shoe Adjustment - 206-05-4 Major Parking Brake Service wn... . gg tps 206-05-5, REMOVAL AND INSTALLATION Parking Brake Shoos fev >, . seen 208-056 Parking Brake Handle . [206-056 Parking Brake Lover (Wagon), Colum Shit (Ute). pean si 208-05-7 IRS Parking Brake Cable Routing } 206-05-7 Beam Axle Parking Brake Cable Routing 206-05-8 (0172008 2008.0 BA Falcon208-05-2 Parking Brake and Actuation ‘SPECIFICATIONS ‘Torque Specifications Description Tn [Adjustment Nut 23 Parking Brake Serew 6 (rat 1000 | T.4—12.4 2030 fantto the operation of ‘Torquing of hardware 1s S9F the system 206-05-2 ‘687680 en (01/2008 2008.0 BA Falcon206-05-3 Parking Brake and Actuation 206-05-3 DESCRIPTION AND OPERATION Parking Brake — Sedan The parking brake is hand operated. The parking brake utlises a dedicated rear drum brake system. The service brake rotor also serves as the parking brake drum. The operating cable Is routed from the parking brake control assembly 10 the equalizer. The Fear cables connect the equalizer assembly to the rear drum brakes. NOTE: The following shoe and cable adjustment procedures are to ensure correct cable/shos settings, the five click position to check for locking whee's is ot ciectly related to the efforviravel to hold the Vehicle on a grade, vnich will vary dependent on a umber of factors and could exceed five clicks. Parking Brake — Ute/Wagon Floor shift vehicles have a hand operated parking broke, Column shit utility vehicles have a seat mounted hhand operated park brake with a return latch which allows the lever to return to the rest postion after boing engaged. The engagement status of the park brake is indicated by a warning lamp which is, iluminated when the park brake is on. An audible ‘waming chime is activated if the vehicle is driven away with the park brake engaged. The parking brake utilises a dedicated rear drum brake system, The service brake rotor alsa serves a the parking brake drum. The operating cable is routed from the parking brake control assembly to the equalizer. The rear cables Connect the equalizer assembly to the rear drum brakes. NOTE: The following shoe and cable adjustment procedures are ta ensure correct cable/shoe settings, the four click position to check for locking wheels is not directly related to the efforttravel to hold the vehicle on grade, which will vary dependent on a rhumber of factors and could exceed 4 clicks. 687682 en (0172008 2008.0 BA Falcon208-05-4 Parking Brake and Actuation 208-05-4 GENERAL PROCEDURES Parking Brake Cable Adjustment Parking Brake Shoe Adjustment Hand-Operated (Floor Shift) Adjustment 41. Adjust the parking brake shoes as described in 1. Raise the vehicle and suitably suppor. this section. 2, Remove rear wheel. 2. Fully release the park brake lover. Re-apply lever 3. Remove service se brake caliper from the (one dick only. ‘mounting plate. Refer to Section 206-04. 3. Tighten cable adjuster nut (under vehicle) until", Remove brake rotor by slowly turing and puling ‘minimum drag is first fet onthe rear wheels when Gatyards simultaneously kaoping the rake rr rotating wheels by hand, ‘square with the axle. I the brake rotor jams whilst 4. Apply the lever a futher 3 cloks removing, donot fre it of. Push the brake rotor '5. Check thal the rear wheels cannot be rotated by back tits crginal postion and attempt removal hand. again 6. Fully release the park brake lever and check rear 6+ Disconnect parking brake cable from the Fens betta a ae OS a parts of doubtful strength or quality due to ‘soolouration from eat or overstvess, oF are worn, they should be replaced. 6. Using a verier caliper. measure shoe assembly diameter as close as practical to the centre of the lining material -— QA ® Cm» ©) LIN ; \. WRT QPS aw won OCS fiom [Deseranon Adjusting Seren Adjusting Nat Shoe oid Down Sarg Screw Tapper Adjust shoe diameter to 180 6-180.8 mm by turning the adjuster nut clockwise to increase ameter. 8, Inspect brake rotor for wear and damage. Discard worn or damaged brake rotors. 8 Check torque on pictip tube mounting hardware. 9, Install brake rotor. 98. Check PIB waming ight operates by first click. 10. Install service dis brake caliper and torque 7. Check operating levers at park brake are in the “OFF position and that there is mirimum ‘learance only between levers and cable eye, 40. Check PIB returns to floor af i's own accord ‘mounting bolts to specification. when in OFF position, 11, Install rear wheel 12. Connect parking brake cable to the operating lever (687683 en (01/2008 2008.0 BA Falcon206-055 Parking Brake and Actuation 206-05-5 GENERAL PROCEDURES (Continued) 13. Repeat 20 12 for the opposite siée parking 8. brake. 14, Adjust the parking brake cable in aocordanoe with 9. tho procedure described in this section. Major Parking Brake Service 1 4. Raise the vehiate. " 2. Remove rear wheel, dis brake caliper and rotor. 42 3. Remove and discard f= Adjusting Nut 3 Adjusting Sorew 13, © Adjusting Pawi 14 2 Tappet ® Pushrod 4. Remove and discard the operating lover and dust 16 cover assembly 6 5. Clean backing plata. The cleaning fluid must be @ high flash point oikfree solvent such as triciowethylene or acetane. These cleaning fluids are usually highly flammable and harmful i ‘vapours are inhaled for prolonged periods. ‘Manufacturer warnings and recommendations should be strictly adhered to. Ensure actuation cavity in backing plate is free from grease and any other contamination. 6. Install lover and dust cover assembly. Slide the lavar onto the dust cover notehes. Insert the lever ‘and dust cover assembly into the backing plate With the lever cable retainer end positiones downward. Refit the dust cover by stretching it (over the cast retainer on the back plate. ausvoer? em [Description rt Dust Cover iz Laver is [Cable Retainer ie Dust Cover Notohes 7. Ltbricate actuation cavity and tappet. AX caution: Ensure cavity internal bore is fully covered with grease. Install adjustment paw to the backing plate with pop rivet provided. ‘Adjustment paws are left and right hand, Ensure ‘ortect fitment Install parking brake adjustment scrow to fully home position in notched adjusting nut Back of 1/4 of a tur, Install sorew and qut assembly into the backing Plate on the adjustment pavé side. Keep the shoo ‘Slot parallel with the backing plate face. Install pushrod into tappet. Install pushrod and tappat into backing plate. Ensure pushrod set correctly in lever sockot by holding the lever into the backing plate whilst inserting pushrod and tappet. loan excess grease away using a clean rag Install shoe and lining assembly. Refer to Parking Brake Shoe Replacement in this section. 17. Repeat 2 to 14 for opposite side parking brake. 687685 en (0172008 2008.0 BA Falcon208-05-6 Parking Brake and Actuation 208-05-6 REMOVAL AND INSTALLATION Install new shoe assembly. AX caution: Ensure hands are clean. Position shoe assembly over the axle shaft. ‘The shoe will be on the outboard side of the ‘actuation mechanism. Slide the shoe towards the hold-down spring engaging the shoo tips. in both the adjusting screw and the tappst slots. ‘The shoe assembly must be resting against 3 ppads on the backing plate with the branding facing outboard. Install new hold-down springs and their attaching sores. Tighten sorew to 2-5 Nm. AX caution: ensure the are fully seated. Inspect sho z position. Shoe must be central on the backing jeserpion plate and both tips located in the slots Boot Correctly. Check the actuation mechanism. fAgquster Nox Manually apply he paiking brake operation | a rf the mechanism does not operate, the [-—}-— parking brake must be disassembled and Acuster Pav reassembled. [Shoe & Lining 410. Adjust shoe diameter. Refer to parking brake [& [Sei tapping Screw ‘shoe adjustment in this section [Fold Down Spring 111, Repeat procedure for the oppesite side parking [Back Plate: brake. Parking Brake Handle Removal 1. Remove driver seat 2, Remove 3 M8 Screws from handle 3, Remove HEX Sorew 32x14 2 Remove rar whoo, dis brake caper lorand | Remeve pci. 3. Remove or disconnect holdsdown springs by _—_Ute/Wagon ‘undoing is attaching screw. 4. Remove the parking brake shoe by gently lifting the shoe over the axle flange, the shoe will pivot {rom the actuation mechanism. Once clear af the flange, disconnect from the actuation mechanism and discard, 2 AX cauTion: Ensure the actuation ‘mechanism is notaisturbed. An elastic band | ‘may bo used to contain the mechanism. 5. Clean debris and dust avay from the backing Plate sing a clean re9. o 6. Adjust paring brake adjustment screw ofuly ce home position in the notched adjustment nut then Ausoesr2 backoff ofa tum, 7. Alig the shoe slots in both the adjusting sorew ‘and the tappet tobe parallel with the backing Plate face Removal and Installation 1. Raise the vehicle, (687686 on (01/2008 2008.0 BA Falcon206-05-7 Parking Brake and Actuation 206-05-7 REMOVAL AND INSTALLATION (Continued) 4, Rotate P-Clps. 6. Release cable from park brake. ST S| 52 Ni ausooser * 4-<————|12.8 No 5. Release cable from park brake. Installation 4, Reverse removal procedure. IRS Parking Brake Cable Routing Removal 4. Remave parking brake handle as shown previously inthis section. 2. Route Park Brake cable to rear of Differential ausoces3 Installation 1. Reverse removal procedure, Parking Brake Lever — Column Shift (Ute) Removal 4. Remove2 retaining bolts, [340 Nm 3. Unclip cable as shown, ausnoseo 2. Remove bracket outboard of RH front seat assembly. 3, Remove 2 HEX Screws 3214. 687689 en (0172008 2008.0 BA Falcon1206-08-8 Parking Brake and Actuation 208-08-8 REMOVAL AND INSTALLATION (Continued) Installation 1. Reverse removal procedure Beam Axle Parking Brake Cable Routing Removal 1. Loosen and remove adluster nut 2. Disconnect cables from equaliser bracket, support brackets and from Banksia lever. wagon ‘587689en (01/2008 2003.0 BA Falcon208-08-0 Parking Brake and Actuation 206-059 REMOVAL AND INSTALLATION (Continued) UK otro! auso22s7 NOTE: Nole on LPG Ute there are two sels of cotton roels to support cable over the lenght af the LPG tank. Installation 1. Route cables per diagrams above. 2, Ensure cable ferrules and white clips are seated into equaliser. 3. Fit adjuster nut and adjust system as per sedan Ga7600 en (01/2008 2008.0 BA Falcon