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PARKING BRAKE SYSTEM


F BRAKES

                                                                                                                                                           A




                                                                                               SECTION
                                                                             PARKING BRAKE SYSTEM
                                                                                                                         PB                                B



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                                                                                                                                                           E
                                                              CONTENTS
PARKING BRAKE SYSTEM ..................................... 2       .          PARKING BRAKE SHOE .......................................... 5    .         PB
 On-Vehicle Service .................................................. 2
                                                                   .           Components ............................................................ 5
                                                                                                                                                 .
   PEDAL STROKE .................................................. 2
                                                                   .           Removal and Installation ......................................... 5
                                                                                                                                                 .
   INSPECT COMPONENTS ................................... 2        .             REMOVAL ............................................................ 5
                                                                                                                                                 .         G
   ADJUSTMENT ..................................................... 2
                                                                   .             INSPECTION AFTER REMOVAL ........................ 6             .
PARKING BRAKE CONTROL .................................. 3         .             INSTALLATION .................................................... 6
                                                                                                                                                 .
 Components ............................................................ 3
                                                                   .          SERVICE DATA AND SPECIFICATIONS (SDS) ....... 7                    .
                                                                                                                                                           H
 Removal and Installation ......................................... 3
                                                                   .           Parking Drum Brake ................................................ 7
                                                                                                                                                 .
   REMOVAL ............................................................ 3
                                                                   .           Parking Brake Control ............................................. 7
                                                                                                                                                 .
   INSTALLATION .................................................... 4
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Revision: 2004 November                                                 PB-1                                                     2004 FX35/FX45
                                     PARKING BRAKE SYSTEM

PARKING BRAKE SYSTEM                                                                                  PFP:36010

On-Vehicle Service                                                                                         AFS001TJ

PEDAL STROKE
q    When parking brake pedal is operated with a force of 200 N (20.4 kg, 44.9 lb), make sure the stroke is
     within the specified number of notches. (Check it by listening and counting the ratchet clicks.)
        Pedal stroke     : 4 - 5 notches
INSPECT COMPONENTS
q    Make sure the components are attached properly (check for looseness, backlash, etc.).
q    Check parking brake pedal assembly for bend, damage and cracks, and replace if necessary.
q    Check cable for wear and damage, and replace if necessary.
q    Check parking brake warning lamp switch for malfunction, and replace if necessary.
ADJUSTMENT
q    To perform adjustment operations, remove tire from the vehicle with power tool.
1.   Insert a deep socket wrench to rotate adjusting nut and loosen
     cable sufficiently. Then, return pedal.
2.   Using wheel nuts, fix disc to hub and prevent it from tilting.




                                                                                                       SFIA1139E



3.   Remove adjusting hole plug installed on disc. Using a flat-
     bladed screwdriver, turn Adjuster in direction A as shown in the
     figure until disc rotor is locked. After locking, turn adjuster in the
     opposite direction by 5 or 6 notches.
4.   Rotate disc rotor to make sure there is no drag. Install adjusting
     hole plug.
5.   Adjust cable as follows:
a.   Operate pedal 10 or more times with a force of 490 N (50 kg,
     110 lb).
b.   Rotate adjusting nut with deep socket to adjust pedal stroke.                                    PFIA0295E
     CAUTION:
     Do not reuse adjusting nut after removing it.
c.   When parking brake pedal is operated with a force of 200 N (20.4 kg, 44.9 lb), make sure the stroke is
     within the specified number of notches. (Check it by listening and counting the ratchet clicks.)
        Pedal stroke     : 4 - 5 notches
d.   With pedal completely returned, make sure there is no drag on rear brake.




Revision: 2004 November                             PB-2                                      2004 FX35/FX45
                                 PARKING BRAKE CONTROL

PARKING BRAKE CONTROL                                                                            PFP:36010
                                                                                                                  A
Components                                                                                             AFS001TK




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                                                                                                SFIA1943E
                                                                                                                  K
   1.   Device assembly             2.   Spring insulator             3.   Return spring
   4.   Lock plate                  5.   Front cable                  6.   Return spring
   7.   Rear left cable             8.   Rear right cable             9.   Pin                                    L
   10. Adjusting nut

Removal and Installation                                                                               AFS001TL

REMOVAL                                                                                                           M
1.  Remove front kicking plate (driver side). Refer to IP-12, "(A) Front Kicking Plate (LH/RH)" .
2.  Remove front body side welt (driver side). Refer to EI-37, "BODY SIDE TRIM" .
3.  Remove dash side finisher (driver side). Refer to IP-10, "INSTRUMENT PANEL ASSEMBLY" .
4.  Remove instrument lower panel (driver side). Refer to IP-10, "INSTRUMENT PANEL ASSEMBLY" .
5.  Remove adjusting nut.
6.  Remove front cable installation bolts, nuts, and lock plate, then remove front cable from the vehicle.
7.  Remove heat insulator between center tube and rear propeller shaft.
8.  Remove exhaust center muffler. Refer to EX-3, "EXHAUST SYSTEM" .
9.  Remove propeller shaft. Refer to PR-7, "Removal and Installation" .
10. Remove rear disc caliper and disc rotors. Refer to BR-26, "Removal and Installation of Brake Caliper
    Assembly" .
11. Remove parking brake shoe, and remove rear cable from toggle lever. Refer to PB-5, "PARKING BRAKE
    SHOE" .



Revision: 2004 November                             PB-3                                   2004 FX35/FX45
                                    PARKING BRAKE CONTROL

12. Remove right and left rear cables installation nut, bolt, and remove right and left rear cable assembly from
    the vehicle.
INSTALLATION
1.   Refer to "Components" for tightening torque. Install in the reverse order of removal.
     CAUTION:
     Do not reuse adjusting nut after removing it.
2.   Adjust parking brake. Refer to PB-2, "ADJUSTMENT" .




Revision: 2004 November                              PB-4                                      2004 FX35/FX45
                                  PARKING BRAKE SHOE

PARKING BRAKE SHOE                                                                              PFP:44060
                                                                                                                 A
Components                                                                                            AFS001TM




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                                                                                               SFIA1167E
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   1.   Back plate                 2.   Anchor block               3.   Toggle lever
   4.   shoe                       5.   Adjuster                   6.   Return spring
   7.   Anti-rattle spring         8.   Retainer                   9.   Anti-rattle pin                          L
Removal and Installation                                                                              AFS001TN

REMOVAL
WARNING:                                                                                                         M
Clean brakes with a vacuum dust collector to minimize the hazard of airborne particles or other mate-
rials.
Be careful of the following:
q    Remove disc rotor only with parking brake pedal completely in the returned position.
q    If disc rotor cannot be removed, remove as follows.
1. Fix disc rotor in place with wheel nuts and remove disc rotor
     plug. Using a flat-bladed screwdriver, rotate adjuster on adjuster
     assembly in direction B to retract and loosen brake shoes.




                                                                                                  PFIA0309E




Revision: 2004 November                            PB-5                                   2004 FX35/FX45
                                       PARKING BRAKE SHOE

INSPECTION AFTER REMOVAL
Lining Thickness Inspection
q    Check thickness of lining.
        Standard thickness (A)         : 3.2 mm (0.126 in)
        Repair limit thickness (A)     : 1.5 mm (0.059 in)




                                                                                                        SBR021A


Drum Inner Diameter Inspection
q  Check drum inner diameter.
        Standard inner diameter       : 190 mm (7.48 in)
        Maximum inner diameter        : 191 mm (7.52 in)
Other Inspections
q  Check shoe sliding surface for excessive wear and damage.
q  Check anti-rattle pin for excessive wear and corrosion.
q  Check return spring for sagging.
q  Check adjustor for rough operation.
                                                                                                        SBR768A
q  Check either visually or with a vernier caliper to see if there is
   any excessive wear, cracks, or damage inside drum.
INSTALLATION
Be careful of the following:
q   Refer to "Component Parts Location" and apply brake grease to the specified points during assembly.
q   Assemble adjuster so that threaded part expands when rotating
    it in the direction shown by the arrow.
q   Shorten adjuster by rotating it.
q   When disassembling adjuster, apply PBC (Poly Butyl Cuprysil)
    grease or silicone based grease to the threads.
q   After replacing brake shoes or disc rotors, or if brakes do not
    function well, perform break-in operation as follows.
1. Adjust parking brake pedal stroke to the specified stroke.
2. Perform parking brake break-in (drag run) operation by driving
    the vehicle under the following conditions:                                                    SFIA0153E


        Drive forward
        q Perform the following

        q Vehicle speed approx. 40 km/h (25 MPH) set (forward)

        q Parking brake operating force approx. 100 N (10 kg, 45lb) set

        q Distance approx. 100m (328ft)

3.   After break-in operation, check lever stroke of parking brake. Readjust if it is no longer at the specified
     stroke.
     q To prevent lining from getting too hot, allow a cool off period of approximately 5 minutes after every
        break-in operation.
     q Do not perform excessive break-in operations, because it may cause uneven or early wear of lining.




Revision: 2004 November                              PB-6                                      2004 FX35/FX45
                           SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS)                                                             PFP:00030
                                                                                                                A
Parking Drum Brake                                                                                   AFS001TO


   Type                                                                           DS19HC
                                              Standard thickness (new)        3.2 mm (0.126 in)                 B
   Brake lining
                                              Wear limit thickness            1.5 mm (0.059 in)
                                              Standard inner diameter (new)   190 mm (7.48 in)
   Drum (disc)                                                                                                  C
                                              Wear limit of inner diameter    191 mm (7.52 in)

Parking Brake Control                                                                                AFS001TP
                                                                                                                D
   Control type                                                                  Foot pedal
   Number of notches [under force of 200 N (20.4 kg, 44.9 lb)]                  4 - 5 notches
   Number of notches                                                                                            E
                                                                                  1 notches
   when warning lamp switch comes on


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Revision: 2004 November                                      PB-7                         2004 FX35/FX45
                     SERVICE DATA AND SPECIFICATIONS (SDS)




Revision: 2004 November              PB-8                    2004 FX35/FX45



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