"DOCUMENT UNCONTROLLED IF PRINTED"
DOC #

TSB1405

PROCESS NAME
DIESEL (SOM) PS REAR BRAKE CABLE
ROUTING/REPLACE (Replaces TSB1301)

PAGE

REVISION

STATION

BY

DATE

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A

SER

DBaker

9/10/2014

SB-10056992-7919

Read process before beginning. If you do not understand any part please contact: Chris Ward, Director of Parts and Warranty at 1-866-953-5555 or by Email @ [email protected].
Good Mechanics safety practice must be followed on any repairs.
Safety practices should include but not be limited to properly supporting the chassis, axles, blocking tires, and a work area free of clutter.
Repair shops safety rules must be followed and safety equipment used. O.E.M. Battery and Auxiliary Battery MUST be disconnected.
The purpose of TSB1405 is to replace a damaged PS rear brake cable.
Labor Operation Code:TSB1405.
Labor Time Allowance: 1.0.
TOOLS REQUIRED
1- Screw gun.
2- 3/8 Socket for screw gun.
3-140 lb. Torque Wrench.
4-1/2" Drive, 22 MM Socket.
5- (2) 17in Combination Wrenches.
6-1/2" Drive, 8-12" long Extension.
7-Ratchet Strap.
8-Needle Nosed Pliers.
9-Flat Screwdriver.
10- Hoist System, one able to raise and support bus.

Kit: 2000948 includes.
PARTS LIST
1. (1) ARBOC# Part#1405783, Parking Brake Cable 3/8x105"
2. (1) ARBOC Part# 616144, Bolt, Hex Head 1/4-20 x 3/4".
3. (1) ARBOC Part# 721811, Bolt, Hex Head 1/4-20 x 1-1/4".
4. (2) ARBOC Part# 1190442, Locknut Nylon Insert 1/4-20.
5. (2) ARBOC Part# 1057595 1/2" P Clamp, Closed 1/2" Vinyl Coated.
6. (1) ARBOC Part# 1305971, Clamp Park Brake Cable Passenger Side Inside.
7. (1) ARBOC Part# 1305972, Clamp Park Brake Cable Passenger Side Outside.
8. (48, INCHES) ARBOC Part# 1406966, 1/2" Conduit, Liquid Tight Flexible Non Metallic.
9. (2) ARBOC Part#616155, Hex Head Cap Screw 3/8-16x1 Perma Plate Tuf-Torq.
10. Electrical Tape (Purchase locally).

Step 1: Pull bus onto hoist to raise unit to a comfortable working height.
Step 2: Do a quick inspection of both the passenger side parking brake cable looking for possible damage. Signs of damage are: damage to the
exterior sheathing, broken cable, or sharp bends in the cable that would prevent smooth cable operation. If damage is found in the passenger side
parking brake cable, a replacement cable will need to be ordered from ARBOC parts and service at 1-866-953-5555.

Example of damage: Parking brake cable with damage to the exterior
sheathing, exposing the metal binding around the parking brake cable.

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Example of damage: Broken parking brake cable.

If damage is found on the parking brake cable, you will have to remove the rear wheel in order to access the connections .

Step 3: Begin removing the mounting hardware from the passenger side parking brake cable. First, remove the P-clamp located on the driver side
chassis main rail located in front of rear axle. Second, remove the vinyl coated P-clamp from the differential cover plate. Reinstall mounting bolt and
tighten. Third, cut the black plastic wire tie installed on the passenger side J-hook.

Remove black vinyl coated p-clamp that mounts cable to flange of chassis
rail.

Cut black cable tie that secures the parking brake cable to the jhook cable routing retainer.

Remove the vinyl coated p-clamp from the differential cover plate and discard. Reinstall the mounting bolt and tighten. The clamp may be located on
the left or right side of the differential cover plate.
Step 4: Release the parking brake cable: Locate the two (2) parking brake cable splice brackets located along the outside edge of the driver side chassis
main rail. Using a six (6') foot ratchet strap, hook one (1) end of the strap to the front cable splice clip located in front of the transmission support cross
member, hook the other end to the rear splice clip located in front of the trailing arm mounting bracket. Tighten ratchet strap. Remove section of
parking brake cable from between the two (2) cable splice clips. Save both cable splice clips and section of brake cable.

Hook one (1) end of the strap to the front cable splice

Transmission support

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Hook the other end to the rear splice clip located
in front of the trailing arm mounting bracket.
Tighten ratchet.

Step 5 : Remove section of parking -brake cable from
between the two (2) cable splice clips. Save both cable
splice clips and section of parking brake cable. Clip
behind transmission cross member.

Using needle nose pliers, depress the two (2) tabs on the blue plastic retaining clip to remove cable from
splice clip. Caution do not break tabs . Save clip.

Using needle nose pliers, and a flat
screwdriver depress the tabs on the
silver retaining clip to remove the
cable from the metal brake cable
bracket.

PASSENGER SIDE
Step 6: Pull passenger side parking brake cable from the driver side of the unit over to the passenger side. Inspect cable for damage to cable that would
require replacement. Check the length of passenger side parking brake cable, if cable only measures 95" the cable will need to be changed to 105" cable.
Order: Passenger side parking brake cable, ARBOC part# 1405783, Cable Parking Brake 3/8 x 105.

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Step 7: If passenger side parking brake cable is secured to the passenger side air shock casting with a vinyl coated p-clamp, the clamp will need to be
replaced with the two (2) part cable clamp. In order to install the two part brake cable clamp you will have to remove the rear wheel. Install new
parking brake cable clamps to exterior side of air spring tower. Clamp is made up of two parts an interior clamp that bolts to the air spring tower,
(ARBOC PART# 1305972) and an exterior clamp (ARBOC Part# 1305971) that bolts to the interior clamp using a 1/4-20 x 3/4" hex head bolt, ARBOC
Part# 616144 and a 1/4-20 nylon locknut, ARBOC Part# 1190442.

Remove "P" style clamps from passenger side air shock casting.
Keep mounting bolt in place. Will be used to secure clam shell
parking brake cable clamp in location. Discard p-clamps.

If bus is equipped with the two (2) part clam shell bracket, remove the
outside clamp only. Do not discard clamp. Note different directions of bolts.
For detail of bracket see next picture.

ARBOC Part# 1190442, locknut
nylon insert 1/4-20. ARBOC
Part#
616144, bolt hex head 1/4-20 x
3/4". Bolt used to attach
exterior clamp to
interior clamp.
ARBOC Part# 1305971, clamp park brake
cable passenger side interior. Bolts to the
exterior.

ARBOC Part# 1305972 clamp park brake cable
passenger side exterior. Bolts to the interior.

Step 8: Mount clamp assembly to exterior of air spring casting and route cable through clamp as shown. Use bolt and nut that mounted vinyl coated
p-clamp. If hardware is missing use a 1/4-20 x 1-1/4" hex head bolt, ARBOC Part# 721811 and 1/4-20 nylon locknut, ARBOC Part# 1190442. Cut any
extra bolt thread length off flush with edge of nut.

Reference pictures of passenger side air shock casting with park brake cable clamp
installed.

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Step 9: Route cable forward securing just in front of PS rear
tire to the floor frame with (1) ARBOC Part#616155 hex
head cap screw 3/8-16x1 perma plate tuf-torq and (1) pclamp ARBOC Part# 1057595 1/2" p-clamp closed 1/2"
vinyl coated . Continue running cable towards the middle
of the bus over the frame rail. Secure cable again to the
floor with another (1) ARBOC Part#616155 hex head cap
screw 3/8-16x1 perma plate tuf-torq and(1) p-clamp
ARBOC Part# 1057595 1/2" p-clamp, closed 1/2" vinyl
coated just to the passenger side of the drive shaft.

Yellow line represents the path of the parking brake cable.

Step 10: Add protective sheathing to the passenger side parking brake cable by installing ARBOC Part#
1406966, 1/2" conduit, liquid tight flexible non metallic . Begin at the rear of trailing arm bracket
install an approximately 48" long piece to cover the parking brake cable up to about the driveshaft.
Secure ends of conduit in place with several wraps on electrical tape.

Step 11: Repeat steps 4 and 5 to reconnect end of cable.

Step 12: To reinstall wheels. Torque wheel to 140 ft./lb.

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