| Special
tools needed: You'll need a very good drop light, headlight spring
tool (illustrated 1.), 3/8" socket screw driver, needle nose pliers, very
small screw driver, dental floss, silicon sealant, a 3" cut-off wheel
(whizzer), and a homemade wire spring tool.
Begin
by drilling out the 3/16" factory rivets securing rotor to hub (ill.
2). If rivets are missing the rotor has been serviced before. If
rivets are present mark the rotor and hub such that relative positioning
is maintained. This minimizes runout of the wheel and is why the factory
riveted them originally. Remove caliper while keeping steel brake line
attached. This will minimize the need for bleeding later. The factory recommends
removal of the brake line to prevent damage to it. Your call, remember
that each time a steel brake line is removed and reinstalled the flanges
and seats experience wear.
Remove
the
upper connecting spring using the headlight spring tool (ill.
3). Next remove side springs using socket screw driver by pushing
in and turing 1/4 turn. Spread both shoes apart from each other and remove.
Servicing
the actuating lever is the most important part of this job and
generally the most difficult. Note that when this assembly corrodes and
seizes, use of parking brake causes the shoes to twist and jam the wheel,
which in turn cause excess wear to the positraction clutches in the differential.
We recommend replacing it with its stainless counterpart. If yours is free
and you're tempted to leave it in place, at least grease it. This assembly
cannot be removed as a unit. We use a 3" cut-off wheel (whizzer) to cut
it in half (ill. 3). The new unit must be assembled in the
car and is extremely difficult. Each of the two pieces is marked L
or R
for location to the proper side of the car (ill. 4).
All references to left or right of a car are made from the drivers seat,
that is with the driver looking forward. The instructions accompanying
the stainless hardware explicitly diagram the orientation of both the actuating
levers and adjuster sprockets (ill. 5). The lever is placed
onto the wheel back plate first with the piece containing the pivot pin
through the slot. The other half is then placed onto the pivot pin. With
grease having been applied to both sides the pivot pin, the shaped washer
and retainer clip placement are manageable. The retainer clip will start
and stay in the pin groove because of the grease. Needle nose pliers are
used to secure it properly. This work is done from the underside looking
up (ill. 6).
Prepare
for shoe installation by applying silicon to the shoe pin
base and prop into position until silicon has dried. Pins should be at
a slight out- ward angle and pulled out as much as possible (ill.
6). Compress at least the rear shoe retainer spring using
dental floss string as shown (ill. 7).
Install
the rear shoe with the upper long connecting spring attached. Place
shoe spring and its retainer over the pin. Insert socket screw driver through
the wheel hub access hole and onto spring retainer, push and turn 1/4 turn
to secure. A properly secured pin will have its little flanges seated into
grooves present in the spring washer-like retainer. Use a cigarette lighter
to burn the string which will release spring tension and secure the brake
shoe.
Install
the front shoe and connect the upper connecting spring after the
retainer spring has been installed. We use the headlight spring tool for
installing the upper spring and the homade wire hook tool for installing
the lower because the wire hook is thinner. Install the shoe retainer spring
and washer like retainer. Check actuator lever to insure proper fit into
brake shoe slots.
Attach
one end of the lower connecting spring to a brake shoe. Grease
adjuster sprocket threads and ends. Adjust sprocket all the way in, (turn clock-
wise). Locate and orient adjuster sprocket with slotted end and sprocket
toward rear of car for left side. Slotted end and sprocket favor the front
of the car on the right side. (Illustrated on accompaning instructions
with hardware kit) Attach the loose end of the lower connecting spring
to the brake shoe, securing both shoes completely. Straight alignment tabs
and install new park brake cable as necessary (ill. 9).
Adjusting
the shoes is done in the same manner as regular old fashioned brake
shoes using a screw driver instead of a brake spoon. Install the rotor
and secure with at least three lug nuts for proper alignment and be sure
to align access holes in the rotor with corresponding holes in hub. Remove
any rivet remnants if present (ill. 10). Rotate rotor while
looking in access hole for adjuster sprocket. Stick a medium sized screw
driver into the access hole and pry the sprocket counter clockwise or
have it unscrew itself from its threaded housing in a manner to stop the
rotor from turning (about 15 - 20 clicks). Now ratchet the sprocket
in the other direction about 8 clicks to properly neutralize the brake
shoes. The rotor should free wheel. If there is any drag loosen it 2 or
3 more clicks. Although primitive in appearance this system works very
well with positive results when exerting a reason- able amount of pressure
by pulling on the actuator lever for testing. At this point if there are
any problems with the functioning of the system when testing by hand the
rotor must be removed and all components carefully inspected. Most problems
are related to the actuating linkage.
Install
the caliper. Many systems we have encountered are tight making
reinstallation of a caliper difficult. Here's a clue that always works
on the tough- est systems. Catch the bottom edges of the pads on both sides
of the rotor's outer surfaces. Use a piece of sheet metal as a prop if
necessary. Many auto parts stores sell such a tool, known as a brake pad
installation tool. The pads are now crooked are not likely to slide the
rest of the way down. Crack the brake bleeder screw loose while wiggling
and pushing the caliper downward. Works every time without applying
excessive pressure.
Bleed the entire brake system. If they feel real good
bleed them anyway. A good test to detect or induce
air into a marginal system is to drive the car on a
highway on a hot day for several hours. It is advisable
to test the brakes from time to time during the test
when they are not needed.
Proper bleeding sequence starts with the right rear
(furthest away from master cylinder), then left rear
then right front and finish with left front.
The completed job
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