Supplement # 1 - Attachment III
OVERVIEWThis procedure will instruct you on how to modify the parking brake control assembly. This modification includes cutting off a portion of the pawl referred to as the kickout tab, and installing a bracket designed to force the pawl into positive engagement with the sector. The bracket is secured to the control assembly with a self-tapping screw.
To prevent damage to any interior trim item, the control assembly must be removed from the vehicle to perform the cutting and drilling steps of the modification procedure. Also, please note that many of the repair steps are written for specific model year coverage. Read these instructions carefully before you begin.
REMOVAL
1. Install a memory saver and disconnect the battery ground cable.
2. Remove the shifter knob.
3. Carefully unsnap the forward bezel from the console and disconnect the electrical connectors. On 1999-2001 model year vehicles, disconnect the main console harness connector. See Figure 1.
4. On 1994-2000 model year vehicles, open the console compartment door. Remove the rubber plugs, then remove the screws from beneath the plugs and remove the bin. See Figure 2.
5. On 1994-1998 model year vehicles, disconnect the main harness connector. See Figure 3.
NOTE:
On 2001 model year vehicles, two of the console retainer screws are located inside the bin.
6. Remove the four (4) console retainer screws, pull the parking brake handle to an upright position and remove the console assembly from the vehicle.
7. Loosen the control assembly retaining bolts 23 turns and allow the tension on the parking brake cable to pull the assembly rearward. Retighten the nuts.
8. On 2001 model year vehicles, be sure to apply parking brake (lever in the upward position). Make sure the self-adjust pawl is fully engaged in the sector, then position the flat plate bracket on the parking brake control assembly as shown in the illustration. Center punch the side of the control assembly at the center of the bracket mounting hole. See Figure 4.
9. Lower the parking brake handle back down, then disconnect and remove the parking brake indicator lamp switch. See Figure 5.
10. Remove the parking brake control assembly retaining bolts.
11. Release cable tension by pulling the control assembly forward far enough to rotate the self-adjuster reel while an assistant inserts a suitable steel lockpin through the hole in the lever and behind the cam on the sector gear. See Figures 5 and 6. This locks the sector gear in the "cable-released" position.
12. Disconnect the cable barrel from the self-adjuster reel and remove the control assembly from the vehicle.
CONTROL ASSEMBLY MODIFICATION
1. Position the control assembly in a vise.
CAUTION
The plastic handle cover must be removed or it will be damaged during the cutting procedure.
Covers are not serviced separately.
2. On 1994-2000 model year vehicle control assemblies, remove the plastic handle cover by disengaging the locking tabs (one on each side) from the underside of the handle using a small screwdriver or other suitable tool.
CAUTION
Be sure to cut only the kickout tab. Do not cut the handle or any other part of the control assembly.
3. Using a suitable cutoff tool, remove 11-13 mm from the end of the kickout tab on the self-adjust pawl. Remove any burrs. See Figure 6.
CAUTION
Drill through the top metal surface only. Do not drill through the entire control assembly.
4. On 2001 model year vehicles, locate the center punch mark on the side of the control assembly. Drill a 4.4 mm (5/32-inch) hole at the center punch mark.
5. Thoroughly clean all metal shavings and grinding/drilling debris from the control assembly.
6. Apply Ford LEAD-FREE Multi-Purpose Grease Spray (F5AZ-19G209-AA) or equivalent to the control assembly self-adjuster pawl and sector.
7. Reinstall the handle cover (1994-2000 model year vehicles).
8. Remove the control assembly from the vise.
INSTALLATION
1. Insert the parking brake cable barrel into the hole in the self-adjuster reel, then route the cable around the reel.
2. Position the control assembly in the car by sliding the rear mounting tab under the console support bracket then line up the front mounting tab with the bolt hole.
3. Install the bolts. While holding the control assembly as far rearward as possible, tighten the bolts to 18 Nm (13 lb-ft).
WARNING
KEEP YOUR FINGERS AWAY FROM THE PARKING BRAKE CONTROL ASSEMBLY TO PREVENT INJURY.
CAUTION
Do not remove the lockpin without first making sure the parking brake cable is properly connected to the control assembly. Pin removal releases the tension in the ratchet wheel causing the spring to unwind and release tension. If the pin is removed without the cable properly connected, the entire assembly must be removed to reset the cable tension.
4. Remove the lockpin.
CAUTION
The torque specification on the self-tapping screw is very low. Do not use power tools to tighten this screw. Do not overtighten the self-tapping screw or the threads in the hole will strip. If this occurs, the entire control assembly must be replaced.
5. Apply and release the parking brake control four (4) times, ending with the lever pulled up to its maximum apply position. Make sure the self-adjust pawl tooth fully engages the sector gear (the paw tooth must not be "perched" between two teeth of the gear). See Figure 7.
^ On 2001 model year vehicles, position the flat plate bracket on the control assembly. Make sure the upper tab of the bracket is flush against the control assembly and the bracket is positioned as far rearward as possible so the foot of the bracket is against the pawl. Install the self-tapping screw and tighten to 3.2 Nm (29 lb-in). See Figure 8.
^ On 1994-2000 model year vehicles position the over-bracket on the control assembly as shown in the illustration. Make sure the over-bracket mounting hole is aligned with the lockpin hole on the control assembly. Install the self-tapping screw and tighten to 3.0 Nm (27 in-lb). See Figure 9.
6. Install and connect the parking brake indicator lamp switch.
7. Install the console and install the retainer screws. On 1994-1998 model year vehicles, connect the main console harness connector.
8. On 1994-2000 model year vehicles, install the bin and bin retainer screws, then install the rubber plugs. Close the console compartment door.
9. On 1999-2001 model year vehicles, connect the main console harness connector.
10. Connect the electrical connectors, if equipped, then snap the forward bezel into position. Install the shifter knob.
11. Connect the battery ground cable and remove the memory saver.
12. Apply and release the parking brake control several times. Make sure the parking brakes apply and release, the BRAKE indicator lamp on the instrument panel comes on when the parking brakes are applied when the key is on, and the lamp goes off when the parking brakes are released.