Article No. 87-8-14

BRAKE - PARKING - PARTIAL OR TOTAL LOSS OF CABLE TENSION - VEHICLES BUILT PRIOR TO 02/01/87

BRAKE - PARKING - "POPPING NOISE" AND RELEASE OF CABLE TENSION - VEHICLES BUILT PRIOR TO 02/01/87

BRAKE - PARKING - REVISED CONTROL ASSEMBLY
LIGHT TRUCK: 1986-87 AEROSTAR


ISSUE: A "popping" noise and/or a noticeable loss of parking brake system cable tension, may occur during application. This intermittent condition is caused by a partial engagement of the self-adjusting pawl against the sector tooth of the ratchet wheel. The system will function normally upon reapplication of the parking brake control.

ACTION: To correct this, install a new design parking brake control assembly (E69Z- 2780-A) with provision for a removal pawl lock-out pin for better sector tooth engagement. Refer to the following service procedure.

Units Built Prior To 02/01/87 with

Original Control

The revised control can be installed using the procedure described in the Aerostar Shop Manual, Section 2-06.

Units Built After 02/01/87 with

Revised Control

To remove the revised control, rewind the revised control, or to release tension in the cable system to remove the rear cables or axle assembly, the Shop Manual removal procedure is being modified as follows:

1. Remove parking brake boot cover to gain access to control.

Figure 10:

Figure 11:

2. Insert a steel pin through holes as shown in Figure 10. The self-adjusting spring lock-out pin is installed per the Aerostar Shop Manual procedure for control assembly removal. A new service control assembly will already have this pin in place so that it can be installed in a vehicle. The pawl lock-out pin must be inserted from the inboard side of the control (larger hole) at a slightly upward and forward angle, then swept downward and rearward to be inserted through the smaller hole (Figure 11). This locks the pawl out of the sector.
3. After the pawl lock-out pin is inserted, the control may be removed by using original removal procedure, refer to the Aerostar Shop Manual. After control is removed from vehicle, pawl lock-out pin may be removed; it is not required for installation.

NOTE: Both pins must be removed after cables are hooked up for proper parking brake adjustment. Lock-out pins can be fabricated from a 1/8" steel rod, 2 to 3 inches long.

PART NUMBER PART NAME CLASS

E69Z-2780-A Parking Brake Control B

OTHER APPLICABLE ARTICLES: None
WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual
OPERATION: SP870814A
TIME: 0.4 Hr. DLR. CODING: Basic Part No. 2780 - Code: 07