Installation

Tool Required
^ 999 5225 Mandrel
^ 999 5351 Mandrel
^ 951 2050 Angle Gauge
^ 999 2861 Counterhold
^ 999 5350 Spacer
^ 999 5340 Counterhold

1. Ensure that the trailing arm and stub axle end piece surfaces are clean before installation.





2. Check that the cable cover sleeve O-ring is undamaged. Press the cover sleeve onto the stub axle end piece.





3. Install the stub axle. Use new screws. Tighten crosswise to 35 Nm (26 ft. lbs.) and angle-tighten to 60°. Use angle gauge.





4. Connect the brake cable to the segment. Thread the cable into its cover.





5. Connect the segment to the cable. Install the segment to the axle and lever. Install the circlip, ensure that the circlip is properly located in its groove.





6. Install:
a. Tunnel bracket with 4 screws.
b. Connectors (black, grey).
c. Storage compartment cover.
d. Cover under handbrake lever red.
7. Install cigarette lighter panel.

NOTE: On certain models, install diagnostic unit socket onto panel.





8. Install gasket between the stub axle end piece and brake backing plate.





9. Install:
a. Brake backing plate and brake shoe retaining springs. Tighten upper screws to 25 Nm (18 ft. lbs.), and lower screws to 20 Nm (15 ft. lbs.).
b. The brake cable bracket on the brake backing plate, early models only.
10. Install brake shoes and adjustment mechanism.
11. Clean and install ABS-sensor.
a. Use a soft brush for cleaning.
b. Install the ABS-sensor. Only applies if the stub axle has been replaced. Tighten to 10 Nm (7.4 ft. lbs.).





12. Replacement of toothed wheel.
a. Pry the toothed wheel off the hub. Use mandrel, spacer and counterhold.





b. Press on toothed wheel. Use mandrel and counterhold. Take care to install the toothed wheel square on the hub.
c. Check toothed wheel position when installing.





13. Install the hub.
a. Ensure that the axle stub is clean.
b. Use a new nut. Tighten to 120 Nm (89 ft. lbs.) and angle-tighten to 30°. Use angle gauge.
c. Check that there is no play in bearing after installation.
14. Install cover. Use mandrel.
15. Ensure that contact surfaces on the disc and hub flange are clean.
16. Install disc and guide pin. Tighten guide pin to 10 Nm (7.4 ft. lbs.).





17. Adjust the parking brake. Adjust brake shoes until the brake disc cannot be turned. Then undo the adjustment mechanism four to six notches.
18. Install brake caliper. Use new screws. Tighten to 60 Nm (44 ft. lbs.).





19. Install the brake pipe in the mounting clips. Install the three-way junction on the left hand side.
20. Install wheel. Hand tighten wheel bolts. Tighten crosswise to 110 Nm (81 ft. lbs.).