Mercedes-Benz Sprinter / Dodge Sprinter. Manual — part 194

(4) Unclip the guides at the frame cross members

for the front cable at the vehicle (Fig. 30).

(5) Pull off the locking clips at the floor opening

and pull the front brake cable down and out (Fig.
30).

(6) Press together the locking ring and pull out the

front brake cable to the front (Fig. 30).

(7) Remove the front park brake cable at the vehi-

cle using special tool 9289.

REMOVAL - REAR

(1) Raise and support the vehicle.
(2) Remove the rear tires.
(3) Remove the park brake shoes.
(4) Remove the park brake cables from the shoe

(Fig. 31).

(5) Remove all the connections on the hand brake

cable (Fig. 31).

(6) Remove the park brake cable lock (Fig. 31).

Observe the installed position of the brake
cable lock for reference on installation.

(7) Remove the hand brake cable from the anchor

plate (Fig. 31).

(8) Remove the park brake cable from the vehicle.

Compress the locking ring on the pulley unit.

INSTALLATION

INSTALLATION - FRONT

(1) Install the front park brake cable to the vehi-

cle.

(2) Clip the cable guides at the frame cross mem-

bers (Fig. 32).

(3) Install the front park brake cable to the hand

brake lever (Fig. 29).

(4) Reconnect the front park brake cable to the

pulley unit (Fig. 32).

(5) Adjust the parking park.
(6) Lower the vehicle.

Fig. 29 FRONT PARK BRAKE CABLE AT LEVER

1 - LOCKING CLIP
2 - LOCKING PIN
3 - CABLE STRAP

Fig. 30 REMOVING FRONT PARK BRAKE CABLE AT

THE VEHICLE

1 - UNCLIP CABLE GUIDES
2 - LOCKING CLIP
3 - LOCKING RING PRESSED TOGETHER

Fig. 31 REAR PARK BRAKE CABLE REMOVE /

INSTALL

1 - PARK BRAKE ADJUSTER
2 - PARK BRAKE CABLE MOUNTING

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BRAKES - BASE

5 - 25

INSTALLATION - REAR

NOTE: Route the park brake cable free of tension
and the risk of chafing.

(1) Install the hand brake cable to the anchor

plate (Fig. 31).

(2) Install the park brake cable lock (Fig. 31).
(3) Install all connections on the hardware cable

(Fig. 31).

(4) Install the park brake cables to the shoe (Fig.

31).

(5) Install the park brake shoes.
(6) Install the rear wheels.
(7) Adjust the park brakes.
(8) Lower the vehicle.

ADJUSTMENTS

ADJUSTMENT - PARKING BRAKE CABLES

(1) Loosen the bolts of the mounting brackets (Fig.

33).

(2) Insert a drill bit or an allen wrench with a 6

mm diameter between the mounting bracket and
front lever (Fig. 33).

(3) Push the mounting bracket back until the front

brake cable is free of play and without tension (Fig.
33).

(4) Tighten the bolts to the mounting bracket

Tighten to 25 N·m (221 in. lbs.) (Fig. 33).

(5) Remove the 6 mm diameter drill bit or allen

wrench (Fig. 33).

(6) Tighten the hand brake lever one notch (Fig.

33).

(7) Clamp the eccentric clockwise until the wheels/

disc brake rotors can still be turned with the force of
the hand (Fig. 34).

(8) Tighten the clamp bolt (Fig. 34).

(9) Release the hand brake lever.
(10) Check the wheel for free movement.

LEVER

REMOVAL

(1) Disconnect the front brake cable from the pul-

ley unit.

(2) Remove the front brake cable from the hand

brake lever (Fig. 29).

(3) Remove the circle cover (Fig. 35).

Fig. 32 FRONT PARK BRAKE CABLE

1 - RETAINING CLIP
2 - LOCKING PIN
3 - FRONT PARK BRAKE CABLE
4 - RETAINING CLIP
5 - PARK BRAKE CABLE ADJUSTER

Fig. 33 PARK BRAKE ADJUSTER

1 - LOOSEN MOUNTING BOLTS
2 - 6 mm ALLEN WRENCH
3 - MOUNTING BOLTS TIGHTENED
4 - FREEPLAY WITH NO TENSION

Fig. 34 PARK BRAKE ADJUSTMENT

1 - ECCENTRIC CLOCKWISE
2 - CLAMP SCREW TIGHTENED

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BRAKES - BASE

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(4) Remove the bolts on the hand brake lever (Fig.

35).

(5) Pull the cover off the hand brake lever (Fig.

35).

(6) Disconnect the hand brake check switch and

wiring harness from the hand brake lever (Fig. 35).

(7) Remove the hand brake lever (Fig. 35).

INSTALLATION

(1) Install the hand brake lever (Fig. 35).
(2) Reconnect the hand brake check switch and the

wiring harness to the hand brake lever (Fig. 35).

(3) Install the cover to the hand brake lever (Fig.

35).

(4) Install the bolts on the hand brake lever.

Tighten to 25 N·m (221 in. lbs.) (Fig. 35).

(5) Install the circle cover (Fig. 35).
(6) Install the front brake cable to the hand brake

lever.

(7) Connect the front brake cable to the pulley unit

(Fig. 35).

SHOES

REMOVAL

REMOVAL - (SRW)

(1) Raise and support the vehicle.
(2) Remove the rear wheels.
(3) Remove the disc brake rotor.

(4) Disconnect the front park brake cable from the

pulley unit. Do not remove the rear park brake
cables.

(5) Remove the retracting springs using special

tool 9280 (Fig. 36).

(6) Remove the adjuster (Fig. 36).
(7) Remove the pressure springs using special tool

9281 (Fig. 36).

(8) Remove the rear park brake shoes (Fig. 36).

Pull the park brake shoes apart at the bottom
and remove them together with the adjuster.

REMOVAL - (DRW)

(1) Raise and support the vehicle.
(2) Remove the rear wheels.
(3) Remove the wheel flange ring.
(4) Remove the disc brake rotor.
(5) Disconnect the front park brake cable from the

pulley unit. Do not remove the rear park brake
cables.

(6) Remove the retracting springs (Fig. 37).
(7) Remove the adjuster (Fig. 37).
(8) Remove the pressure springs (Fig. 37). by

depressing with your fingers and twisting.

(9) Remove the rear park brake shoes (Fig. 37).

Pull the park brake shoes apart at the bottom
and remove them together with the adjuster.

Fig. 35 HAND BRAKE LEVER

1 - LOCKING PIN
2 - COVER
3 - HAND BRAKE LEVER
4 - HAND BRAKE CHECK SWITCH
5 - WIRING HARNESS
6 - BOLT
7 - HAND BRAKE CABLE
8 - BOLT
9 - RETAINING CLIP
10 - CIRCLE COVER

Fig. 36 PARK BRAKE SHOES

1 - PARK BRAKE SHOES
2 - PRESSURE SPRING
3 - RETRACTING SPRING (SHORT HOOK EYE)
4 - RETRACTING SPRING (LONG HOOK EYE)
5 - CABLE LOCK
6 - ADJUSTER

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BRAKES - BASE

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CLEANING - REAR DRUM IN HAT BRAKE

Clean the individual brake components, including

the support plate exterior, with a water dampened
cloth or with brake cleaner. Do not use any other
cleaning agents. Remove light rust and scale from
the brake shoe contact pads on the support plate
with fine sandpaper.

INSTALLATION

INSTALLATION - (SRW)

NOTE: Preassemble the retracting spring with the
short hook eye from the inside together with the
adjuster wheel at the bottom. Fit the preassembled
park brake shoes on the brake carrier.

(1)

Ensure that the cable lock moves easily

before installing shoes.Install the park brake
shoes.

(2) Install the lower retracting spring using special

tool 9280.

(3) Install the hold down springs using special tool

9281.

(4) Install the upper retracting spring using spe-

cial tool 9280.

(5) Install the adjuster.
(6) Install the front park brake cable to the pulley

unit.

(7) Install the disc brake rotor.
(8) Install the rear wheels.
(9) Adjust the parking brakes.

(10) Lower the vehicle.
(11) Pump the brake pedal several times to check

the operation of the brakes before moving vehicle.

INSTALLATION - (DRW)

NOTE: Preassemble the retracting spring with the
short hook eye from the inside together with the
adjuster wheel at the bottom. Fit the preassembled
park brake shoes on the brake carrier.

(1)

Ensure that the cable lock moves easily

before installing shoes.Install the park brake
shoes.

(2) Install the lower retracting spring.
(3) Install the pressure hold down springs by

depressing with your fingers and twisting to lock in
place.

(4) Install the upper retracting spring.
(5) Install the adjuster.
(6) Install the front park brake cable to the pulley

unit.

(7) Install the disc brake rotor.
(8) Install the rear wheel flange ring. Tighten to

200 N·m (148 ft. lbs.).

(9) Install the rear wheels.
(10) Adjust the parking brakes.
(11) Lower the vehicle.
(12) Pump the brake pedal several times to check

the operation of the brakes before moving vehicle.

ADJUSTMENTS

ADJUSTMENT

(1) Raise and support the vehicle.
(2) Remove the rear wheels.
(3) Turn the adjusting wheel through the hole of

the wheel lug bolt until it is no longer possible to
rotate the rear wheel (Fig. 38).

(4) Loosen the adjusting wheel 3-4 teeth divisions

(Fig. 38).

Fig. 37 PARK BRAKE SHOES WITH DUAL REAR

WHEELS

1 - HOLD DOWN PIN
2 - PRESSURE SPRING
3 - ADJUSTER
4 - UPPER RETRACTING SPRING
5 - LOWER RETRACTING SPRING
6 - CABLE LOCK
7 - LOCKING PIN
8 - BRAKE CABLE
9 - PARK BRAKE SHOE

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BRAKES - BASE

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