IK0400154 Service Bulletin/Repair Instructions

IK0400154 ­ Hydraulic Brake System Park Brake Inspection and Adjustment Procedures
Page 1 of 11
Countries:
UNITED STATES, MEXICO
Availability:
ISIS, Bus ISIS, FleetISIS, NotSIR Revision:
Document ID: IK0400154
Major System:
BRAKES
Created:
4

9/5/2017
Current Language: English
Last Modified: 9/21/2017
Other Languages: NONE
Author:
Viewed:
James Santos
567

Less Info
Coding Information
Hide Details
Copy Link
Copy Relative Link
Bookmark
Add to Favorites
Print
Provide Feedback
View My Bookmarks
Helpful
Not Helpful
8
1
Title : Hydraulic Brake System Park Brake Inspection and Adjustment Procedures

Applies To : Hydraulic Brake system equipped with 04GBJ Park Brake
CHANGE LOG

Please refer to the change log text box below for recent changes to this article:

09/05/2017 - Initial Article Release

09/13/2017 - Added damper removal procedure before park brake cable adjustment

09/21/2017 - Added Bracket, Clamps, and Spring Assembly Alignment plus Pedal adehsive.



DESCRIPTION

This document will guide the user through 04GBJ Park Brake Inspection and adjustment procedures.
SYMPTOM(s)

Diagnostic Trouble Code(s) & Dashboard Indicator Light(s):

DTC/Light
Description
N/A

Customer Observations or Concerns

Unit will not operate in reverse due to parking brake lock-up. Tech/Driver may find heat indications on park brake drum. Driver may experience

"shuttering" from rear of vehicle while driving.
SPECIAL TOOL(s) / SOFTWARE

Tool Description
Tool Number
Comments
Vernier Caliper
N/A
Obtain Locally
Instructions
SERVICE PARTS INFORMATION

Kit Description
Part Number
Quantity

Notes

Required
KIT SHOE AND LINING VERSION2
2605826C91
1
KIT PARK BRAKE LEVER CAM PLATE

SCREW
2605827C91
1
KIT BRAKE SPRING
2605828C91
1
CABLE, PARKING BRAKE ADJUSTER
2605829C91
1
KIT ADJUSTER HARDWARE
2605830C91
1
KIT SHOE HOLD DOWN BRACKET
2605831C91
1
DRUM, BRAKE DLM
3543437C1
1
https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...
10/5/2017
IK0400154 ­ Hydraulic Brake System Park Brake Inspection and Adjustment Procedures
Page 2 of 11
DIAGNOSTIC STEP(s)
To prevent unexpected movement of the vehicle and possible serious personal injury or

death, park the vehicle on a flat, level surface, set the parking brake, turn the engine off

and chock the wheels to prevent vehicle from moving in both directions.
To prevent property damage, personal injury and / or death, parking brake front cable

must have 1.50 inches (38 mm) or more of thread engagement in the adjustment

turnbuckle.

Step 1: Release park brake, remove drum and inspect for heat damage to drum or linings. Also inspect adjustment cable for damage See figures

below:
https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...
10/5/2017
IK0400154 ­ Hydraulic Brake System Park Brake Inspection and Adjustment Procedures
Page 3 of 11
Figure #3: Damaged Cable

Step 2: If any damage is present, replace drum and shoes along with adjustment cable. Make certain Adjustment cable is installed behind the Cam

Plate. See figure 4.

Note: If Starwheel free spins adjustment cable needs to be replaced.
https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...
10/5/2017
IK0400154 ­ Hydraulic Brake System Park Brake Inspection and Adjustment Procedures
Page 4 of 11
Figure # 4: Adjustment Cable Behind Cam Plate
Service Procedure

Note: Follow all steps below to adjust driveline parking brake after inspection and replacement of parking brake components.

Adjustment With Drum OFF­ Primary Procedure

1. Use a 12inch caliper, or inside micrometer, to measure the inside diameter of the drum. Subtract 0.025 inches from the drum inside diameter

measurement. Set the measurement caliper to this value, and lock the set screw.

2. Rotate the axle input flange yoke as necessary to provide clearance for the measurement caliper.

3. Place the pre-adjusted caliper over the shoes at the center of the shoes.

4. To adjust brake, rotate the starwheel until the shoes touch the measurement caliper jaws. It is necessary to disengage the adjuster lever away

from the starwheel.
https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...
10/5/2017
IK0400154 ­ Hydraulic Brake System Park Brake Inspection and Adjustment Procedures
Page 5 of 11
Figure #5: Shoe to Drum Running Clearance

Adjustment with Drum Installed - Alternate Procedure

1. With the engine off, the battery disconnected, and the tires blocked to prevent vehicle movement, place transmission in neutral and fully release

the parking brake. It will be necessary to raise the rear wheels off the ground, in order to allow rotation of the drum. Support the vehicle with

suitable floor stands

2. Insert the adjuster lever tool or a thin flat bladed screw driver through the adjusting slot in the backplate and push on the adjuster lever to

disengage it from the adjuster starwheel. Insert a brake adjusting tool (or flathead screwdriver) through the adjusting slot and move the starwheel

teeth downward to expand the brake shoes outward. Continue expanding the shoes until the drum can not be rotated by hand.

3. Now adjust the starwheel teeth upward to retract the shoes until the drum just begins to rotate freely by hand (without drag from the shoes).

Parking Brake Cable Overview
https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...
10/5/2017
IK0400154 ­ Hydraulic Brake System Park Brake Inspection and Adjustment Procedures
Page 6 of 11
Figure # 6: Parking Brake Assembly, Front Cable and Turnbuckle

1. Parking brake assembly
3. Adjustment turnbuckle
2. Front Cable
4. Intermediate cable
When the parking brake assembly pedal is depressed tension is applied thru the front cable, adjustment turnbuckle, intermediate cable and rear cable.

Cable tension is transferred forcing the brake shoes against the parking brake drum to prevent vehicle movement.
https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...
10/5/2017
IK0400154 ­ Hydraulic Brake System Park Brake Inspection and Adjustment Procedures
Page 7 of 11
Figure #7: Parking Brake Drum, Rear Cable, Spring, Support Bracket and Intermediate Cable

1. Rear cable
4. Intermediate cable
2. Cable spring assembly
5. Parking brake drum
3. Rear cable mounting support bracket
Remove Park Brake Pedal Spring Damper
1. Before cable adjustment park brake pedal damper will need to be removed and discarded. Refer to figure 8.
https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...
10/5/2017
IK0400154 ­ Hydraulic Brake System Park Brake Inspection and Adjustment Procedures
Page 8 of 11
Figure #8: Park Brake Pedal Spring Damper
2. Using a small screw driver with a flat blade lift the retaining clip slightly on the top of the ball socket and then pull the gas spring off the ball stud.

Refer to figure 9.
Figure #9: Park Brake Dampener

3. Discard damper.

4. Once damper is removed, rubber pad on park brake pedal will need to be adhered to the pedal using LOCTITE 430 obtained locally. Add 5 dots

about 1/4" in diameter, one in each corner and one in the middle of the pedal.

Note: after removal pedal will fully return at a faster rate.
Park Brake Cable Alignment
https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...
10/5/2017
IK0400154 ­ Hydraulic Brake System Park Brake Inspection and Adjustment Procedures
Page 9 of 11
1. Make Certain extension/clamps on intermediate cable are aligned and not touching park brake cable. This will ensure that park brake cable has no

restrictions to fully release and apply. Refer to figure 10.
Figure #10: Clamps Aligned and Not Touching Park Brake Cable
Rear Cable Support Bracket/ Cable Spring Assembly Alignment.

1. Make certain bracket and cable spring assembly are at a 90 degree (straight up and down). This will ensure spring assembly does not come in

contact with frame upon park brake release or apply. Please refer to figure 11.

2. If not aligned please loosen two bolts, adjust and re-tourqe bolts to 41- 50 ft lbs (56-68 nm)
https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...
10/5/2017
IK0400154 ­ Hydraulic Brake System Park Brake Inspection and Adjustment Procedures Page 10 of 11
Figure #11: Bracket and Spring Assembly Aligned
Parking Brake Cable Adjustment

NOTE: NEW SPEC FOR MEASUREMENT STARTS AT 11mm MAX 14mm

1. Release parking brake loosen jam nut to adjust turnbucke item number 3 in figure 6.

2. Apply and release parking brake all the way to the floor (bottomed out) Perform this step 3 times before continuing to step 3.

3. Fully apply park brake, using Vernier calipers measure critical distance in figure 12. Spec is 11mm -14mm

4. After correct cable tension adjustment, lock jam nut and proceed to Park Brake Operation section of this document
https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...
10/5/2017
IK0400154 ­ Hydraulic Brake System Park Brake Inspection and Adjustment Procedures Page 11 of 11
Figure #12: Parking Brake Applied Cable Measurement staring 11mm Max 14mm

Parking Brake Operation

1. Upon parking brake release make certain pedal is fully releasing

2. With Parking brake applied Place Vehicle into Drive and Reverse rev engine to 1500 RPM and make certain vehicle does not pull away. If

vehicle pulls away the parking brake cable adjustment will need to be set at the higher end of the spec.

3. Release parking brake and drive forward and reverse making sure no brake drag is present.

4. If any concerns arise while performing operational checks run through brake adjustment steps again and make certain no steps were missed.

5. After all checks are complete return vehicle into service.
WARRANTY INFORMATION

Warranty Claim Coding:

Refer to the Warranty Coding Manual for Group and Noun Codes.
Standard Repair Time(s):

Refer to the SRT Manual for Repair Times
OTHER RESOURCES

Master Service Information Site

Bosch Park Brake Manual

Hide Details
Feedback Information

Viewed:
566
Helpful:
8
Not Helpful: 1

No Feedback Found
Copyright © 2017 Navistar, Inc.
https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...
10/5/2017

SaleBestseller No. 1

Autel Scanner MaxiCOM MK808S: 2026 Bidirectional Tool as MX808S MK808BT Pro M808Z, Work as MaxiCheck MX900 MK900BT, 28+ Service, 3000+ Active Tests, All System OBD2 Diagnostics, OS 11, 10X Faster

💝【Questions? We’re Here Anytime】MK808S is a high-end flagship model that connects via wired OBD2 for faster, more stable, and reliable diagnosis compared to B,.T tools. If you have any questions about setup, activation, features, additional accessories, or update subscriptions, please reach us and we will respond promptly to assist you. It includes 1-Year F.ree Updates (124.5 bucks/year after), and most functions still work after expiration except a few online features. Please note some functions like full TPMS are not supported, reach us for model recommendations.
🔥🔥🔥【2026 NEWLY RELEASED BI-DIRECTIONAL CONTROL】As the 2026 upgraded version of MaxiChek MX808 MaxiDiag MD909 Pro MD906 Pro, our Newest MK808S auto diagnostic scanner for all cars inherits the powerful Bi-directional Control which makes it the most cost-effective scanner (without breaking the bank, same as MK900BT MS906 PRO MS906MAX). Active test is widely used on car subsystems to help you check if the car actuators are all in good condition. Such as windows, rear mirrors, sunroof, wipers...
【28+ MOST POPULAR RESET SERVICE FOR 150 MAKES】Autel versatile OBDII scanenr MK808S, full level-up of MX808, work as MX900, MK900, MK900-BT, supports 150+ car brands worldwide. Like the OBD2 code reader MaxiCOM MK808BT Pro, MK808S is equipped with 28+ hot services including 0il Reset, SAS Calibration, ABS Bleeding, Battery Registration, etc. MK808S ranks top in professional automotive tablets and keeps updating to support more newer modes from 2025 to 2026.
【ALL SYSTEM DIAGNOSTICS, FACTORY-LEVEL SCANNER】The MK808S dealer-level scanner, like Snap-on tools, effectively works all cars for all system diagnostics. It reads/clears codes, displays 5-in-1 Live Data, performs active tests, and special functions for all available modules. With a few clicks, you can easily understand the vehicle's condition. The convenient Wi-Fi printing feature allows you to generate a detailed report, highlighting the exact nature of the problem.
【AUT0 SCAN & AUT0V1N, 10X FASTER】How much have you spent on car maintenance? Even a minor issue can take up a significant amount of time. The MK808S is designed to improve your work efficiency. With its Aut0V1N technology, you can check your car's make, model, and year information with just one click. The Aut0Scan feature automatically scans all of the vehicle's modules and detects any fault codes. Check Aut0V1N compatibility by reaching us at 📞1-833-436-5880. Available Mon-Fri, 9 AM-6 PM EST.

SaleBestseller No. 2

Autel Scanner MaxiCOM MK900BT, 2026 MK900-BT V2.0 Bidirectional Diagnostic Tool, 8in Up of MK900 MX900 MK808S MK808BT MX808S MK808Z, 3000+ Active Tests, 40+ Service, CAN-FD&DOIP, All System, FCA 11 OS

💯【Conta.ct us for Support Directly】If you met any issues about: Received a registered device/ Language Changing/ Function not Support/ Blueto-oth connector malfunction/ Subscription Renewal, please conta.ct us via 📞autelsupply @outlook. com🛣️, we will provide perfect solution for you. ⚠️Note: Autel MK900BT comes with 1-Year Free Software Update, most features will remain active after update subscription expires. For questions regarding updates or need more useful accessories, please conta.ct us via 📞autelsupply @outlook.com🛣️. 2. If you encounter Blueto-oth adapter VCI150 malfunction, please tell us 📞autelsupply @outlook. com🛣️, we will handle it promptly.
🔥🔥🔥【2026 AUTEL FLAGSHIP MK900BT MK900-BT, NEW MODEL OF MK808S MK900 MX900 MK808BT MX808S】2026 newest Autel MK900BT retains all features of MK808S MX900 MX808S MK808Z MK808Z-BT MK808K-BT, while EXTRA added powerful functions (value 2000+ bucks). The Pro-level Autel MK900BT makes a big leaps: 28+➡40+, 50+➡3000+ Active Tests, 2026 NEW✅CAN FD & DOIP protocols ✅Pre&Post diagnostic report ✅WIFI Print ✅Auto VIN&Auto Scan 2.0 ✅Scan VIN/ License ✅Battery Test (Need purcha.se BT506). If found defect or us.ed, please conta-ct 📞autelsupply @outlook. com📞 get perf-ect solut.ion.
🚗【3000+ ACTIVE TESTS (50➡3000+), SAME AS MS906 PRO】Differ from MS906BT MS906 MP808 MK808 MX808 MK808BT only 50 tests, Autel scanner MK900BT escaner automotriz professional offers 3000+ active tests, it can send command to ECUs & monitor actuators operation, quickly locating faulty components. Bidirectional scanning takes your diagnostics to the next level with menu lists 3000+ active tests, such as windows, rear mirrors, sunroof, wipers, fuel injector, coolant fans, radiator fan, AC clutch, coolant pump and more. Note: Functions are not available for all vehicles, please send vehicle VIN to us check compatibility.
🚗【40+ HOT SERVICES FOR 150 MAKES (28+➡40+)】Full level-up of OBD2 code reader MaxiCOM MK808S MK808 MK808Z MX808 MK808Z-BT with 28 service, Autel scan tool MK900BT/ MK900-BT offers 40+ maintenance service on 150+ brands 10,000 vehicles from 1996-2025-2026. Hottest Services like: Oil Reset, ABS Bleed, SAS Calibration, Injector Coding, SRS, Throttle Reset, Gearbox Reset, Battery Registration etc. Added 12+ advanced resets: rain slash light sensor reset, HVA.C/ SUS calibration etc. Welcome to send Vehicle Make>Model>Year>VIN>Functions you required to 📞autelsupply @ outlook . com📞 check compatibility.
🚗【OE ALL SYSTEM DIAGNOSE, AUTO SCAN 2.0: SCAN LICENSE/ AUTO VIN】2026 new release Autel MaxiCOM MK900-BT scan tool embodies all system diagnostic with its 8in display for all vehicles. Like Sna.p-on tools, it can perform ✔Read/Clear Codes✔Displays 5-in-1 Live Data✔Record & Playback Data✔Retrieve Info on all available systems like ABS ECM BCM SRS TCM etc. In addition to Auto VIN technology, Autel MK900BT adds Scan License/ Auto Scan 2.0 to identify vehicle’s VIN/ license, make, year, model, no need manual input; One-click WiFi Printing of Pre&Post comparison diagnostic reports, highlight root causes of problems.

SaleBestseller No. 3

Autel Professional OBD2 Scanner AL319 Code Reader, Enhanced Check and Reset Engine Fault Code, Live Data, Freeze Frame, CAN Car Diagnostic Scan Tools for All OBDII Vehicles After 1996, 2026 Upgraded

【TURN OFF CEL】 This AL319 car scanner diagnostic tool supports Reading and Clearing DTCs, DTC Look Up, displaying Live Data, Freeze Frame & I/M Readiness, view vehicle information, etc., to figure out the root cause of the Check Engine Light (CEL) and turn it off, helping you catch any potential issues early and avoid excessive costs from unnecessary repairs.
【EXTENSIVE APPLICATION】 Autel AL319 Compatible with 7 languages (English, French, Spanish, etc.) and various post-1996 OBD II protocol vehicles (Toyota, Nissan, Honda, Ford, etc.), this OBD II scanner provides accurate and fast diagnosis for worldwide car owners.
【FOR END USER & DIYERS】 This error code reader AL319 is “plug and play” and comes with an easy interface. Even if you’re not familiar with vehicle repair, you can quickly take control of this obd2 scanner, and get the information you want.
【USER-FRIENDLY DESIGN】 This OBD2 scanner and check engine code reader features a patented One-Click I/M Readiness, TFT color display, built-in speaker, LED Indicator etc. The cable is long enough without being too long and getting in the way. No batteries are needed.
【HIGH-QUALITY SERVICES】 12 months war.ranty from the date of purchase and lifetime free update are offered by this Automobile OBDII scan tool. Welcome to contact us via Q&A, email, or hotline, and our after-sale-service team for technical support.

This product presentation was made with AAWP plugin.

Last update on 2026-05-13 / Affiliate links / Images from Amazon Product Advertising API

Buffer Email Facebook Flipboard Hacker News LinkedIn Messenger Mix Pinterest Print Reddit SMS Telegram Tumblr X VK WhatsApp Line Xing Threads Bluesky Copy Mastodon Nextdoor