Drum Brake System: Service and Repair

Removal

WARNING: Clean brake lining with a vacuum dust collector to minimize the hazard of airborne materials or other materials.

CAUTION: Make sure parking brake lever is completely released.

1. Release parking brake lever fully, then remove drum.
If drum is hard to remove, the following procedures should be carried out.





a. Remove adjuster plug. Shorten adjuster as shown to make clearance between brake shoe and drum.





b. Install two bolts as shown. Tighten the two bolts gradually.





2. After removing retainer, remove spring by rotating shoes. Be careful not to damage parking brake cable when separating it.
3. Remove adjuster.
4. Disconnect parking brake cable from toggle lever.





5. Remove retainer ring with a suitable tool. Then separate toggle lever and brake shoe.

Inspection
WHEEL CYLINDER





- Check wheel cylinder for leakage.
- Check for wear, damage and loose conditions.
Replace if any such condition exists.

WHEEL CYLINDER OVERHAUL





- Check all internal parts for wear, rust and damage. Replace if necessary.
- Be careful not to scratch cylinder when installing pistons.

DRUM





Maximum inner diameter: 204.5 mm (8.05 inch)
Out-of-roundness: 0.03 mm (0.0012 inch) or less
- Contact surface should be fine finished with No. 120 to 150 emery paper.
- Using a drum lathe, resurface brake drum if it shows score, partial wear or stepped wear.
- After brake drum has been completely reconditioned or replaced, check drum and shoes for proper contact pattern.

LINING





Check lining thickness.
Standard lining thickness: 4.5 mm (0.177 inch)
Lining wear limit: 1.5 mm (0.059 inch)

Installation
- Always perform shoe clearance adjustment.
- Burnish the brake contact surfaces after refinishing or replacing drums, after replacing linings, or if a soft pedal occurs at very low mileage.
1. Fit toggle lever to brake shoe with retainer ring.





2. Apply brake grease to the contact areas shown.





3. Shorten adjuster by rotating it.





- Pay attention to direction of adjuster.
4. Connect parking brake cable to toggle lever.
5. Install all parts.
Be careful not to damage wheel cylinder piston boots.





6. Check that all parts are installed properly.
Pay attention to direction of adjuster assembly.
7. Install brake drum.
8. When installing new wheel cylinder or overhauling wheel cylinder, bleed air.
9. Adjust parking brake.