NHTSA ID Number: 10130903
Manufacturer Communication Number: IK0400154
TSB/Document Date: 2018-04-02
Summary
Hydraulic Brake System Park Brake Inspection and Adjustment Procedures; only models with Hydraulic Brake system equipped with 04GBJ Park Brake
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:
Created:
5
9/5/2017
Current Language: English
Last Modified: 10/10/2017
Other Languages: NONE
Author:
Viewed:
James Santos
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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.
10/10/2017- Added cusioned clamp part number and clean date for correct 5/8" clamp used with intermediate cable
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
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
CLAMP RUBBER CUSHIONED
3564290C1
1
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IK0400154 Hydraulic Brake System Park Brake Inspection and Adjustment Procedures
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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:
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IK0400154 Hydraulic Brake System Park Brake Inspection and Adjustment Procedures
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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.
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IK0400154 Hydraulic Brake System Park Brake Inspection and Adjustment Procedures
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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.
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IK0400154 Hydraulic Brake System Park Brake Inspection and Adjustment Procedures
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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
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IK0400154 Hydraulic Brake System Park Brake Inspection and Adjustment Procedures
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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.
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IK0400154 Hydraulic Brake System Park Brake Inspection and Adjustment Procedures
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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.
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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
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1. If vehicle was built before 10/12/2017, replace cushioned clamps with the larger 5/8" clamp specified in the parts section of this document. Make
Certain extensions and 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)
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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
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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
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Copyright © 2017 Navistar, Inc.
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TSB/Document ID: IK0400154
Replacement Service Bulletin Number:
MFR Communication Date: 2017-10-10
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: SERVICE BRAKES, HYDRAULIC
MFR Component System:
MFR Component Subsystem:
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