Sunfire L4-138 2.3L DOHC VIN D MFI (1995)
the other brake components should be inspected and serviced for damage (i.e., wheel bearing assembly, parking brake cable, wheel cylinder, etc.).
OVERHEATED - After mechanical repair, return to Step 2.
NOT OVERHEATED - Proceed to Step 4.
4.
With Park Brake Lever Released, pull back the front cable at the rear axle connection. This will create "slack" in the system that had been taken up
by the self-adjust mechanism. This places the cable in the fully released position. Recheck wheel turning effort to insure wheel turns easily by
hand.
FREE - Proceed to Step 6 to evaluate front portion of the park brake system.
NOT FREE - Concern may be in rear brake assembly or rear park brake cable(s). Proceed to Step 5.
5.
Review Mechanical Operation of Rear Brakes and
Cables to look for discrepant or mis-assembled part(s). Inspect rear brake cable for physical condition, correct routing into and inside the rear
brake assemblies and for freedom of interference with adjacent parts. With drums installed, check for proper actuation of the shoes both
hydraulically and with the park brake lever.
The current rear park brake cable is P/N 22651234 and is identified by red tape. If replacement is necessary, verify that the cable being installed is
the correct part number.
Check the operation of the park brake system by fully applying it 3-4 times (to fully adjust) and recheck wheel turning effort to insure wheel turns
easily by hand.
FREE - Proceed to Step 6 to re-evaluate the front portion of the park brake system.
NOT FREE - review mechanical operation of brake and/or cable to look for discrepant or mis-assembled parts.
6.
Inspect Front Park Brake Cable and Lever Assembly for proper installation and operation. Cable should be inspected for pinches (especially near
driver's inboard seat track and rear console bracket), kinks, nicks, or cuts in cable strand coating, etc.
The parking brake cable wire strand is coated with a plastic material that slides against nylon seals inside the conduit end fittings. This plastic
coating is for corrosion protection and reduced parking brake effort. Handling of these cables during servicing of the parking brake system
requires a little extra care. Damage to the plastic coating will reduce corrosion protection and if the damaged area passes through the seal, it may
damage the seal and cause the cable to snag and not fully release. Contacting the coating with sharp-edged tools or with sharp surfaces of the
vehicle underbody should be avoided.
Important:
Plastic coated parking brake cables do not need periodic lubrication.
To check operation of the cable, disconnect both the ends of the front parking brake cable to verify the cable strand moves freely by hand from
either end (approximately 5-10 lb. force):
DAMAGE/INSUFFICIENT OPERATION - Replace front cable, P/N 22603399.
After replacement, return to Step 2 for verification.
7.
The Park Brake Lever Should Be Inspected for proper operation and for the self-adjust feature. It may be checked by pulling the cables down at
the rear axle as in Step 4 and cycling the system 3-4 times. While cycling the system, hold the release button in as this will allow you to hear the
adjustment "clicks." After re-installing the console assembly, recheck for brake drag and possibly a feeling of "tightness" at the lever assembly.
DRAGGING AND/OR "TIGHTNESS" OF OPERATION - Recheck front and/or rear park brake cables for possible mis-routing or cable damage.
Repair and re-evaluate with Step 2.
FREE/NORMAL - Verify no drag condition exists and return vehicle to service.
