CATALOG / brake-cable-service
Template · brake-cable-service
BRAKE CABLE SERVICE
Adjust or replace a brake cable on a mechanical disc or drum brake. Branches on cable-work (adjust vs replace) and brake-type (mechanical-disc vs drum).
Intake: answers gate which atoms compose
brake-type
Brake type (this template covers cable-actuated brakes only). Vehicle context is captured separately at ticket intake.
mechanical-discdrum
cable-work
What cable work is needed?
adjustreplace
Composed steps · 6 atoms in order
atom:intake-consult2 steps
01intake-consult/IC.1
Listen to the customer describe the problem, then ask clarifying questions to confirm the symptom, when it happens, and what changed recently
capture“What did the customer report, in their words?”
capture“What clarifying questions did you ask, and how did they answer?”
NOTENOTE
02intake-consult/IC.2
Set expectations before work begins: the scope of the planned work, what is not included, and the likely outcome
capture“What scope and expectations did you set with the customer?”
NOTE
atom:bay-readiness2 steps
03bay-readiness/BR.1
Clear and stage the work area: bench clear, vehicle secured on the stand, fire-safe location for any battery work
capture“Work area clear and the vehicle secured?”
capture“Photograph the staged work area.”
PASS / FAILPHOTO
04bay-readiness/BR.2
Select and stage the correct tools for the planned job, and put on the PPE the work requires (gloves, eye protection)
capture“Correct tools staged for this job?”
capture“PPE on for the work being done?”
PASS / FAILPASS / FAIL
atom:power-down-and-photo1 step
05power-down-and-photo/1
Power down + photograph cable routing
capture“Vehicle powered down?”
capture“Snap a photo of the cable routing.”
PASS / FAILPHOTO
atom:brake-cable-adjustwhen cable-work = adjust3 steps
06brake-cable-adjust/BCA.1
Pull the lever; note travel — should bite firmly within ~1/3 of total travel and have no spongy feel
capture“Lever bites within ~1/3 travel?”
PASS / FAIL
glossary → brakes/brake-lever
07brake-cable-adjust/BCA.2
Execute the matched cable-adjust branch by brake type
branch on brake-type
Cable adjust — branch by brake type
MECHANICAL DISCmechanical-discmechanical
BCA.mech.1Turn the lever barrel adjuster counter-clockwise to take up cable slack; small increments — 1/4 turn at a time
capture“Barrel adjuster turned; how many 1/4-turn increments?”
VALUE · quarter-turns
BCA.mech.2If barrel maxed out and lever still slow, loosen caliper pinch bolt, take up cable slack by hand, re-pinch; reset barrel to mid-range
capture“Pinch bolt loosened, slack pulled, re-pinched; barrel reset to middle?”
BCA.mech.3Spin wheel; if pad rubs, loosen caliper bolts, hold lever firmly, retorque caliper bolts (this re-centres pads to rotor)
capture“Pads no longer rubbing on rotor when lever released?”
PASS / FAIL
glossary → brakes/brake-cable
DRUMdrum
BCA.drum.1Find the drum adjuster (usually a click-wheel at the backing plate or a barrel at the cable junction); click outward 1 step at a time
capture“Drum adjuster clicks added — how many?”
VALUE · clicks
BCA.drum.2Spin the wheel between clicks; stop when shoes whisper just slightly at every rotation, then back off 1 click
capture“Shoes whisper just barely on every revolution; backed off 1 click?”
PASS / FAIL
08brake-cable-adjust/BCA.3
Final lever pull — confirm firm bite within ~1/3 travel; no rubbing at rest
capture“Final lever feel firm; no resting drag?”
PASS / FAIL
atom:brake-cable-replacewhen cable-work = replace6 steps
09brake-cable-replace/BCR.1
Loosen the cable pinch bolt at the caliper / drum end; pull the cable free; pop the cable end cap off
capture“Cable freed at the brake end; end cap off?”
10brake-cable-replace/BCR.2
Pull the cable out of the housing toward the lever; inspect the inner liner — replace housing if liner is gummy, fraying out, or kinked
capture“Housing inspected — keep or replace?”
DECISION · 2
11brake-cable-replace/BCR.3
Pop the cable out of the lever (squeeze lever, lift cable head out of its seat); discard the old cable
capture“Old cable removed from the lever?”
12brake-cable-replace/BCR.4
Thread new cable through the lever, through every housing segment (with new housing if replaced — match length, cap each end with ferrules), through every cable guide, and out to the caliper / drum end
capture“New cable threaded end-to-end; ferrules on every housing end?”
capture“Snap a photo of any routing the tech wants documented for a future swap.”
PHOTO
infoLubricate the cable lightly before threading — saves the housing from premature wear
13brake-cable-replace/BCR.5
Branch by brake type for the cable-anchoring detail
branch on brake-type
Cable anchor — branch by brake type
MECHANICAL DISCmechanical-discmechanical
BCR.mech.1Pull cable taut by hand with the caliper arm in rest position; pinch-bolt with cable seated in the bolt groove
capture“Cable taut; pinch bolt secured with cable in the groove?”
glossary → brakes/brake-cable
DRUMdrum
BCR.drum.1Pull cable taut so the drum lever sits at rest position; thread into the adjuster nut; lock with the jam nut
capture“Cable seated in drum adjuster; jam nut locked?”
14brake-cable-replace/BCR.6
Cut cable ~30 mm past the pinch bolt; crimp on the end cap; pull lever firmly 5× to stretch the cable, then retension via brake-cable-adjust
capture“Cable cut + end cap crimped; 5 pull-stretches done; ready to adjust?”
PASS / FAIL
atom:findings-handoff3 steps
15findings-handoff/FH.1
Explain the findings and the work done in plain language, without jargon, and confirm the customer understands
capture“How did you explain the findings and work to the customer?”
NOTE
16findings-handoff/FH.2
Communicate any battery findings verbally: state of health, charging guidance, and safety notes, and confirm they were understood
capture“What battery findings did you communicate, and how did the customer respond?”
NOTE
17findings-handoff/FH.3
Communicate any drive-system findings verbally: motor, controller, or sensor behavior observed during service
capture“What drive-system findings did you communicate to the customer?”
NOTE
deviation_rules · 6 declared
ad_hoc_step
a captured step is not in the runbook for the resolved vehicle / brake-type / cable-work branches
missed_step
a runbook step for the resolved branches has no capture in the job record
missing_required_evidence
a step's capture.evidence item went unfilled by the tech's narration
branch_candidate
narration matches a finding pattern (cable fray, housing kink, sticky pull) but no branch was taken
contaminated_pad_kept
narration mentions oil or brake fluid on pads but no pad-replace step was added
dot_mineral_crossover
narration mentions both DOT and mineral brake fluid in the same job record
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