Replacing Brake Cables

Replacing brake cables

Removal

Remove the center console
See Replacing the parking brake lever Replacing the Parking Brake Lever.

Release the parking brake adjuster
See Handbrake, brake shoes, replacing Hand Brake, Brake Shoes, Replacing.

Remove the mechanical cable from its segment




Take hold of the mechanical cable and bend it to the side so that it can be removed.

Secure a heavy wire to the end of the mechanical cable




Bend a thick metal wire (welding rod) as illustrated.
Secure the wire in the cable eyelet. Bend the wire over the eyelet.

Remove the mechanical cable




Remove the seat cushion for the rear seat.
Fold up the floor carpet by the rear seat. Place a wooden block or similar between the carpet and the floor.
Remove the rubber cable grommet by pressing it backwards in the bodywork.

Remove the brake caliper with the holder and the brake disc




Remove the mounting screws for the brake caliper. Hang the caliper from the spring. Use a wire so as not to damage the brake pipe.
Remove the locating pin and the brake disc.

Note! Do not damage the ABS line.

Remove the expander





Remove:
- the return spring at the expander
- the expander. Lift the brake shoe slightly. Grip the expander and pull it outwards to access the cable.
Unhook or pry apart the expander (1) by the mechanical cable to remove it.

Remove the guide sleeve for the cable sleeve




Insert a screwdriver between the guide sleeve lug and the wheel unit. Pry apart slightly to remove the sleeve.

Remove the mechanical brake cable




Remove the clamp (1) by the track rod.
Remove the mechanical cable from its mountings (2).
Pull the mechanical cable from the floor until the welding rod is visible (3).
Remove the mechanical cable from the welding rod.

Note! Leave the welding rod in the hole in the floor.

Installation

Install the cable in the wheel unit




Lubricate the O-ring on the wheel unit lightly using petroleum jelly.
Install and press the guide lug for the cable sleeve into place in the wheel unit.

Note! This is important for the operation of the parking brake.

Install the expander on the mechanical cable





Install:
- the expander on the cable. Press the mounting together to lock the cable in the expander
- the expander between the brake shoes
- the return spring.
Check the function.

Install the brake cable in its clamps




Secure the cable in its clamps and on the welding rod.
Bend the welding rod over the end of the cable.
Install the cable in the hole in the floor.
Press the rubber grommet into the hole in the floor.
Press the mechanical cable into place in its mounting on the bodywork between the heat shield and the fuel tank.
Press the cable between the fuel tank and the edge of the heat deflector (the anti-vibration shield should be inside the edge.)

Lower the car

Pull the cable up to the brake lever




Take hold of the welding rod. Pull the mechanical cable with the sleeve through the bodywork and up to the parking brake lever.
Remove the welding rod.

Install the rubber seal against the bodywork




Take hold of the rubber seal for the mechanical cable. Pull it until the rubber seals against the bodywork.
Fold back the carpet.
Reinstall the seat cushion.

Install the cable to the parking brake segment





Install:
- the cable end on the segment
- the adjuster nut at the parking brake lever.

Install the center console
See Replacing the parking brake lever Replacing the Parking Brake Lever.

Install the brake disc and the brake caliper with the holder




Install the disc locating pin. Tighten to 8 Nm.
Tighten the screws for the caliper holder. Tighten to 60 Nm. Use new mounting screws.

Install the wheel
See Installing wheels Service and Repair.

Adjust the parking brake
First tension the cable by pulling the lever to 400 N.
To adjust the parking brake, see Handbrake, brake shoes, replacing Hand Brake, Brake Shoes, Replacing.