Lokar Connector Cable Under-the-Dash Foot Operated or Under-the-Dash Hand Operated Emergency Brake - Manual

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General Installation Notes:
Please read instructions completely before beginning installation. If you
have any questions please call.
Before starting installation, use wheel chocks to block the vehicle's tires.
Disconnect the negative battery cable before beginning installation.
Make sure the engine, transmission, body and frame are properly
grounded. We recommend applying anti-seize lubricant to all aluminum
threads before final assembly.
Refer to Fig. 1 and Fig. 2 for the component names.
This Lokar Connector Cable is designed to be used with a Lokar Under-the-Dash
Foot Operated or Hand Operated Emergency Brake, and Lokar's Universal Rear
Emergency Brake Cables.
Step 1: Remove the inner wire from the cable housing on the new Lokar
connector cable.
Step 2: Remove the E-clip from the end of the cable housing. Insert the
cable housing into the foot or hand brake mechanism under the dash,
and secure the cable housing with the E-clip as shown in Fig. 3 (foot
brake) or Fig. 4 (hand brake).
Step 3: Route the cable housing back to the rear brake cables.
Step 4: Determine where the single cable adjuster bracket will be mounted.
The single cable adjuster bracket must be aligned with the double
cable adjuster bracket (not included, part of the rear brake cable kit)
so that the cables are being pulled in a straight line, not at an angle.
If you are using Lokar’s Universal Rear Emergency Brake Cables, the
single cable adjuster bracket should be mounted approximately 9-1/2"
in front of the double cable adjuster bracket as shown in Fig. 5.
Step 5: Mount the single cable adjuster bracket to the underside of the
vehicle.
Step 6: It will be necessary to shorten the new connector cable housing.
Make sure that the inner wire is removed from the cable housing. Mark
the cable housing where it lines up with the cable adjuster. If the
cable housing is braided stainless steel, slide the ferrule up the
housing towards the dash, away from the end that is being cut.
DO NOT remove the ferrule from the braided stainless steel housing!
If the cable housing is black universal, remove the ferrule.
TOLL FREE 1-877-469-7440 • [email protected] • www.lokar.com
®
Connector Cable Installation Instructions
for Under-the-Dash Foot Operated or Under-the-Dash Hand Operated Emergency Brake
Connector Cable Installation Instructions
for Under-the-Dash Foot Operated
or Under-the-Dash Hand Operated Emergency Brake
INS0012 Rev. 05/07/14 Page 1 © 2013 Lokar, Inc.
Cable
Housing
5/16"-28 Threaded
Rod With Jam Nuts
Single Wire Union
with 1/4"-28 x 1/4"
Set Screws
Cable Adjuster
Single
Cable Adjuster
Bracket
Cable
Housing
Ferrule Inner
Wire Single Wire Union Assembly
E-Clip
Inner
Wire
Cable
Ball
Fig. 2
Fig. 1
Step 9: When the inner wire is fully installed, you should have at least a foot or more of the inner wire
sticking out of the cable adjuster.
Thread the single wire union assembly approximately 1/2" into the cable union block (not
included, part of the rear brake cable kit).
Step 10: Bring the inner wire up next to the single wire union assembly, and mark the inner wire where
it lines up with the tapered end of the single wire union assembly.
Step 11: Measure 1-3/8" further towards the rear end of the inner wire and make a second mark. Cut
the inner wire at the second mark, so that approximately 1-3/8" of the inner wire can be
inserted into the single wire union assembly. Fig. 6
Step 12: Loosen the set screws using a 1/8" Allen wrench. Insert the end of the inner wire fully into
the single wire union assembly, and tighten the set screws.
Step 13: Adjust all cables as necessary to remove any slack.
Step 6: (Continued) If the brake cable has the braided stain-
less steel housing, wrap tape around the area to
be cut and use an abrasive cutoff wheel or fine-
toothed hacksaw to cut the cable housing at your
mark. If the brake cable has the black universal
housing, cut the cable housing at your mark using
heavy duty 8" diagonal cutting pliers or a hacksaw.
Lokar recommends Klein brand Diagonal Cutting
Pliers, # D2000-28 available at The Home Depot
or through W. W. Graingers, Part # 4A838.
After cutting the cable housing, put the ferrule back
in place at the end of the cable housing. The ferrule
does NOT need to be crimped or otherwise attached
in place.
Step 7: Insert the cable housing and ferrule into the cable
adjuster at the single cable adjuster bracket.
Step 8: Foot Brake Only: Install the inner wire into the cable
housing, starting from under the dash. Make sure the
brake is in the fully "OFF" position. Insert the cable
ball into the slot in the clevis on the foot or hand
brake mechanism under the dash.
Step 8: Hand Brake Only: Install the clevis supplied with the
hand brake onto the inner wire. Make sure the brake
is in the fully "OFF" position.
Connect the clevis to the hand brake handle using
the clevis pin, flat washer, and cotter pin that are
supplied with the hand brake. Then route the inner
wire over the pulley in the hand brake and into the
cable housing.