yo John.
Parking Brake Service Procedure TSB 00-01-03 for 92-94 Bronco & F Series Built Through 4/22/1994 & 93-94 Ranger & Explorer Built Through 5/13/1994 (Scroll Down)
Source: by Ford via Steve83 (Steve, That dirty old truck) at
http://www.supermotors.net/registry/media/283545_1
http://www.supermotors.net/registry/media/283545_1
Parking Brake Cables ('92-96)
IF THE IMAGE IS TOO SMALL, click it.
1 Control Assembly 2780
2 2 Nut M8 x 1.25 Hex Flange 17-23 N-m (13-17 Ft-Lb) N620481-S
3 Cable Assembly, Front 2853
4 Cable Assembly, Intermediate 2A793
5 Equalizer 2A602
6 Bracket 2530
7 Rivet N647097-S
8 Clip, 10 x 10 N800962-S32
9 Screw, Tap 5/16-18 x 3/4 Hex Washer Head 24-30 N-m (18-22 Ft-Lb) 40949-S2
10 Cable and Conduit Assembly, Right 2A635 (Wagner BC132090 / BC94490)
11 Cable and Conduit Assembly, Left 2A809
12 Clip N804729-S11
13 Screw and Washer 5/16 x 18 x .50 Hex Head 17-23 N-m (13-17 Ft-Lb) 57632-S2
14 Steering Column Support 3B139
Park Brake Cable Removal
1.Remove the left kick panel.
2. Disconnect the parking brake indicator light switch connector at the control assembly.
3. Remove the three nuts holding the control assembly to the steering column support. Pull the control assembly away from the steering column support.
4.
Relieve tension on the parking brake system by having an assistant pull on the intermediate cable until all cable is unwound from the control assembly.
5. Insert a 5/32-inch drill bit or equivalent into the hole provided in the control assembly.
6. Disconnect the front cable from the cable connector.
7.Disconnect the barrel end of the cable from the control assembly.
8.Disconnect the cable conduit from the control assembly by inserting a 1/2-inch 12-point box end wrench over the conduit snap fitting to compress the retaining fingers and backing out the snap fitting.
Installation
1. Route the cable end fitting over the cable shoe. Snap the conduit fitting into the control assembly housing. Insert the barrel end into the hole in the track.
2. Position the control assembly to the steering column support and install the three retaining nuts. Tighten to 17-23 N-m (13-17 ft-lb).
3. Connect the front cable to the cable connector.
4. Connect the parking brake indicator light switch connector.
5.
Carefully remove the drill bit from the control assembly. NOTE: The control assembly will tension itself when the drill bit is removed.
6. Operate the parking brake pedal several times. Rotate both rear wheels to be sure that the parking brakes are not dragging.
7. Install the left kick panel.
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& read the This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.
Ford Motor Company has determined that a defect which relates to motor vehicle safety exists in certain 1992-1994 Model Year Bronco, F-150-350 Series Trucks and 1993-1994 Model Year Explorer/Ranger vehicles.
Safety Defect
During rapid pedal application of the parking brake, the pedal may go to the floor with little or no effort. Should this occur, the parking brake system may not achieve full tension, potentially resulting in parking brake ineffectiveness, or diminished effectiveness.
Repairs
At no charge to you, your dealer will install a parking brake lock-in wedge. This wedge retains the adjustment pawl in mesh with the ratchet. Dealers currently have instructions and parts ordering information.
WARNING: DO NOT PARK THE VEHICLE IN NEUTRAL. USE FIRST (1) GEAR AND SET THE PARKING BRAKE FULLY.
NOTE: When the transfer case is in the N (Neutral) Position, the engine and transmission are disconnected from the rest of the driveline. Therefore, the vehicle is free to roll even if the manual transmission is in gear. Do not leave the vehicle unattended with the transfer case in N (Neutral).
NOTE: Always set the parking brake fully and turn off the ignition when leaving the vehicle. Make sure that the gearshift is securely positioned in First (1) gear.
How Long Will It Take?
The time needed for this service is about one-half hour. However, due to service scheduling times, your dealer may need your vehicle for one full working day.
Call your dealer without delay. Ask for a service date and whether parts are in stock. If your dealer does not have the parts in stock, they can be ordered before scheduling your service date. Parts would be expected to arrive within a week.
When you bring your truck in, show the dealer this letter. If you misplace this letter, your dealer will still do the work, free of charge.
AFFECTED VEHICLES:
CERTAIN 1992-1994 BRONCO, F-150/350 SERIES TRUCKS AND CERTAIN 1993-1994 EXPLORER/RANGER VEHICLES EQUIPPED WITH
MANUAL TRANSMISSIONS
OVERVIEW
The parking brake procedures described in this attachment supersede all previous parking brake procedures.
The following instructions have been revised to make them easier to follow. Special emphasis is placed on the installation of the lock-in wedge and verifying that the wedge is properly installed. When installed properly, the wedge WILL NOT fall out.
Except where noted, the illustrations included here are of the Bronco/F-Series. The Explorer/Ranger are similar. PLEASE FOLLOW THESE INSTRUCTIONS CAREFULLY.
NOTE: This recall applies to PARKING BRAKES ONLY. The service brake system is not affected by this recall.
PRELIMINARY CHECKS
1. Park the vehicle on a flat surface. Turn the ignition OFF. Do not apply the parking brake.
2. Check the parking brake control assembly to see if it is a “Cam-In-Post” design. The “Cam-In-Post” design control assembly does not require installation of the lock-in wedge. If the vehicle has a “Cam-In-Post” design control assembly, return the vehicle to the owner.
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TSB 00-01-03 PARKING BRAKE - PROCEDURE FOR SERVICING PARKING BRAKE - SERVICE TIP - BRONCO AND F-SERIES BUILT THROUGH 4/22/1994 AND EXPLORER/RANGER BUILT THROUGH 5/13/1994
Publication Date: DECEMBER 22, 1999
FORD: 1992-94 BRONCO, F-150-350 SERIES
1993-94 EXPLORER, RANGER
ISSUE: When servicing the parking brake or service brake systems where the lock-in wedge has been installed in the parking brake control, additional service procedures will be necessary.
ACTION: When a lock-in wedge part has been previously installed in the parking brake control assembly, it must be removed prior to conducting maintenance procedures from the appropriate Service Manual, Sections 06-04 (Rear Drum Brakes) and 06-05 (Parking Brake System). The wedge must be reinstalled after service is completed. Refer to Service Recall Bulletin 94S91-S3 for lock-in wedge part removal and installation detailed service procedures, part numbers, and diagrams. Be sure to inspect the wedge for damage. If any part of the wedge is broken or damaged, install a new wedge.
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TSB 98-5A-35 Rear Parking Brake Cables Bind - Vehicles Built Before 8/20/96, except chassis cab
Publication Date: MARCH 18, 1998