Recall - Park Brake Lever Replacement
Group: CAMPAIGNNumber: 05-01-006
Date: JULY, 2005
Model: 2005 TUCSON
Subject
PARKING BRAKE LEVER ASSEMBLY REPLACEMENT -
CAMPAIGN 071
IMPORTANT:
DEALERS MUST PERFORM THIS CAMPAIGN ON ALL AFFECTED VEHICLES PRIOR TO CUSTOMER RETAIL DELIVERY AND WHENEVER AN AFFECTED VEHICLE IS IN THE SHOP FOR ANY MAINTENANCE OR REPAIR.
IMPORTANT:
WHEN A VEHICLE ARRIVES AT THE SERVICE DEPARTMENT, ACCESS HYUNDAI MOTOR AMERICA's "WARRANTY VEHICLE INFORMATION" SCREEN VIA DCS INTERACTIVE OR DCS ON-LINE TO IDENTIFY OPEN CAMPAIGNS.
DESCRIPTION:
NOTE:
Please review the entire contents of this package with the appropriate personnel at your dealership.
Some 2005 MY Tucson vehicles may have been produced with a parking brake lever pawl that was not properly manufactured and which may damage the teeth of the parking brake lever ratchet.
This bulletin outlines the repair procedure for removal and replacement of the Parking Brake Lever Assembly with the applicable part numbers.
VEHICLES AFFECTED:
^ Model: 2005 TUCSON vehicles
^ Affected production date range: Produced beginning March 29, 2005 through May 20, 2005
GENERAL INSTRUCTIONS:
If you have affected vehicles in your inventory, you should:
1. Confirm that the vehicle is within the specified model production range and on the "Recall Tracking Inquiry" screen.
2. Confirm that the recall repair procedure has not been previously performed by checking the DCS "on-line" system and use the "Recall Tracking Inquiry" screen function.
3. Complete a repair order and perform the procedure as described in this bulletin.
4. Submit a warranty claim in a timely manner as per the attached warranty information.
PART INFORMATION:
NOTES:
^ The part number for the recall repair replacement part is identified by the letter "C" in the last digit.
^ Install the new parking brake lever assembly identified by a production lot number of "E" or later.
LOT NUMBER DECODING:
^ Lot number "5E15" means that the new parking brake lever assembly was manufactured on May 15, 2005 as shown.
SERVICE PROCEDURE:
NOTE:
Verify that the vehicle was manufactured within the affected production date range and has an open campaign per the DCS interactive screen.
1. Place the vehicle on a hoist.
NOTE:
If a hoist is not available, place the vehicle on a level surface and block the front and rear wheels.
2. Unscrew the floor console front mount tapping screws (2 on each side).
NOTE:
Use care not to scratch the console during service.
3. Using a flathead screwdriver, release the console end cover upper mounting clips.
4. Carefully separate the end cover from the console with your hands.
NOTE:
Use care not to break or lose the clips.
5. Disconnect the power outlet connector if installed.
6. Remove the two 10 mm nuts mounted to the body.
7. Open the armrest lid.
8. Remove the cover inside the armrest.
9. Remove the two 10 mm bolts mounted on the body.
10. Disconnect the seat warmer connector if installed.
11. Raise the brake lever all the way.
12. Lift the floor console and remove the harness clip.
13. Remove the floor console.
14. Remove the 12 mm parking brake lever mounting bolts (4 total).
15. Disconnect the parking brake cables.
16. Install the new parking brake lever assembly in the reverse order of removal.
NOTE:
Make sure the new part color and the lot number are correct.
17. Adjust the exposed length of the parking brake cable adjusting bolt from the equalizer to approximately 11 mm as shown.
18. Pull the parking brake lever with a force of approximately 44 lbs (20 kg) and count the number of clicks, 6 to 7 clicks are the standard values.
NOTE:
Parking brake lever parts removed for clarity (no need to remove surrounding parts to perform the above step).
19. If the number of "clicks" is not within the standard value, adjust the cable length with the equalizer adjusting nut.
NOTE:
The brake indicator light should go out when the brake lever is fully released, and it should light with the lever pulled one click.
20. After the adjustment, check that the rear brakes do not drag with the parking brake lever released.
CAMPAIGN CLAIM INFORMATION:
NOTE:
Submit claims using the Campaign Claim Screen.