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9. Apply and release the parking brake at least two times, allowing the pedal to return each time without any interference. This will cause the wedge to loosen or fall out if it is not installed properly.

10. Place a small screwdriver between the lock-in wedge and the sector gear. Apply a firm, up and down prying force to the wedge. The wedge should feel very stiff, with no movement between the sector gear, wedge and pawl.
If no movement is noted, the wedge has been properly installed. Proceed to Parking Brake Functional Test.
If movement is noted, call 1-800-325-5621 for further instructions.
PARKING BRAKE FUNCTIONAL TEST

NOTE: The parking brake system has been adjusted, checked for proper operation, and a wedge installed. The following parking brake functional test must be performed to verify proper parking brake adjustment.

1. Place the transmission in neutral, then raise the vehicle on a hoist until the rear wheels are off the ground.

NOTE: The vehicle must be supported by the rear axle to maintain curb height.

2. Position two (2) jack stands under the rear axle housing, then lower the hoist until the weight of the vehicle is supported by the rear axle.

3. Firmly apply the parking brake.

4. Verify that the parking brake is applied by trying to rotate the rear wheels by hand.

5. Release the parking brake.

6. Verify that the parking brake is fully released. Check for brake drag by rotating the rear wheels by hand.

7. Raise the vehicle and remove the two (2) jack stands. Lower the vehicle.

8. Turn the ignition to the "RUN" position and verify that the dash brake light is not illuminated.

9. Call 1-800-325-5621 for further instructions if any of the following conditions exist:
a. The rear wheels turn while the parking brake is applied.
b. Brake drag occurs when the parking brake is released.
c. The dash board brake light is illuminated with the parking brake released.

NOTE: In the future, if the parking brakes require adjustment, the lock-in wedge must be removed. The parking brakes must be adjusted according to the procedure on page 5 of this attachment. The lock-in wedge must be reinstalled after the parking brakes have been adjusted.

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.

OTHER APPLICABLE ARTICLES: 94S91-S3
________________________________________________________________________________
SAFETY RECALL 94S91 Supplement 3
Certain 1992-1994 Bronco, F-150-350 Series Trucks and 1993-1994 Explorer/Ranger Vehicles Equipped with Manual Transmissions - Installation of a Parking Brake Lock-in Wedge
December, 1999

Subject: Enhanced Parking Brake Lock-In Wedge Inspection and Service Procedure (See Attachment III)

Reference: Certain 1992-1994 Model Year Bronco, F-150-350 Series Trucks and 1993-1994 Model Year Explored/Ranger Vehicles equipped with Manual Transmission - Installation of a Parking Brake Lock-in Wedge
This supplement (94S91-S3) only affects Technical Instructions (Attachment III) and Labor Allowances. These new technical instructions have enhanced inspection and service procedures. Effective immediately, all Technicians must use these procedures when servicing any vehicles affected by Safety Recall 94S91.
Please discard the original 94S91 bulletin, Supplements #1, and Supplement #2. This supplement (94S91-S3) combines the information from all previous supplements and the original bulletin.

REASON FOR THIS SUPPLEMENT
This supplement only affects the Technical Instructions (See Attachment III). These instructions provide an improved method for inspecting the parking brake lock-in wedge installation. In addition, the service procedures have been enhanced to make them easier to understand and follow.

AFFECTED VEHICLES:
ASSEMBLY PLANT & PRODUCTION DATES - AFFECTED VEHICLES
Original Bulletin (Dated October 25, 1994): Norfolk Assembly Prior to 01/27/94, Michigan Truck Prior to 02/04/94, Ontario Truck Prior to 02/09/94, Kentucky Truck Prior to 02/16/94, Kansas City Assembly Prior to 04/22/94 - Certain 1992-1994 Model Year Bronco, F-150-350 Series Trucks with Manual Transmission
All 1993-1994 Model Year Ranger/Explorer vehicle with Manual Transmission produced prior to 05/01/94

Supplement Number 1 (Dated May 1995):
Edison Assembly 05/01/94 through 05/13/94 - 1994 MY Rangers with Manual Transmission, Louisville Assembly 05/01/94 through 05/12/94 - 1994 MY Rangers and Explorers with Manual Transmissions
Supplement Number 2 (Dated July 1995):
Twin Cities Assembly 05/01/94 through 05/13/94 - 1992 MY F-Series 150-350 trucks with Manual Transmissions

REASONS FOR RECALL: During rapid pedal application, the parking brake pedal, with little or no effort, may go to the floor and the parking brake may be ineffective in holding the vehicle stationary. Should this occur, the self-adjustment pawl may skip over one or more teeth on the ratchet. To correct this condition, a lock-in wedge will be installed in the parking brake assembly. This wedge locks out the self-adjustment mechanism and retains the adjustment pawl in mesh with the ratchet.

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)). ALWAYS SET THE PARKING BRAKE FULLY AND TURN OFF THE IGNITION WHEN LEAVING THE VEHICLE.

WARNING: MAKE SURE THAT THE GEARSHIFT IS SECURELY POSITIONED IN FIRST (1) GEAR. NOTE: IF THE PARKING BRAKE PEDAL MOVES TO THE FLOOR WITH LITTLE OR NO EFFORT WHEN APPLIED, RELEASE AND RESET THE PARKING BRAKE. NEVER LEAVE YOUR VEHICLE UNATTENDED WHILE IT IS RUNNING. IF YOU DO NOT TAKE THESE PRECAUTIONS, YOUR VEHICLE MAY MOVE UNEXPECTEDLY AND INJURE SOMEONE.

QUESTIONS? Claims Information 1-800-423-8851 - Other Recall Questions 1-800-325-5621

LABOR ALLOWANCES:
Operation Description Labor Allowances Labor Operation
Inspect vehicle for previous wedge installation or Cam-In Brake design and using a screwdriver, check wedge for looseness. 0.2 Hours 94S91A
Adjust parking brake, install parking brake wedge, and perform parking brake functional test (Includes Inspection) 0.7 Hours 94S91B
Administrative Allowance 0.1 Hour Misc. Expense Code "ADMIN"
NOTE: The Labor Operation Numbers and Time listed above supersede those listed in all previous supplements to this recall.

PARTS REQUIREMENTS
Part Number Description Quantity Per Vehicle
F4TZ-2L780-C Wedge - Explorer/Ranger (Large size, Black) 1
F4TZ-2L780-D Wedge - Bronco/F-Series (Small size, White) 1
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See also: