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Brake Pad: Service and Repair
Brake Pads
Removal
WARNING: Asbestos fiber dust may be present on brake and clutch assemblies and is hazardous to health if inhaled.
Brake and clutch assemblies should be cleaned using a vacuum cleaner recommended for use with asbestos fibers such as a brake/clutch/service vacuum. The bag must be labeled per OSHA instructions, sealed, and the trash hauler notified as to the bag's contents.
If a vacuum suitable for asbestos is not available, cleaning should be done wet. If dust generation is still possible, technicians should wear government-approved toxic dust purifying respirators. Failure to follow these instructions may result in personal injury.
1. Remove the wheel and tire assembly.
2. Remove the brake caliper clip.
3. Position the caliper aside.
(1) Remove brake caliper bolt caps and the bolts.
(2) Position the caliper aside and support.
4. Remove the brake pads,
^ Remove the outer brake pad from the anchor.
^ Remove the inner brake pad from the caliper piston.
5. To install, reverse the removal procedure.
To remove the rotor, follow one extra step to remove the caliper anchor plate:
6. Remove the bolts and brake caliper anchor plate.
7. To install, reverse the removal procedure.
Brake Drum: Service and Repair
Brake Drum
Special Tool(s): Brake Drum Gauge (134-R0191 or equivalent)
Removal
WARNING: Asbestos fiber dust can be present on brake and clutch assemblies and is hazardous to health if inhaled.
Brake and clutch assemblies must be cleaned using a vacuum cleaner recommended for use with asbestos filters, such as brake/clutch/service vacuum. The bag must be labeled per the Occupational Safety and Health Act (OSHA) instructions, sealed, and the trash hauler notified as to the bag's contents. Failure to follow these instructions may result in personal injury.
WARNING: If a vacuum suitable for asbestos is not available, cleaning must be done wet. If dust generation is still possible, technicians must wear government-approved toxic dust purifying respirators.
The Occupational Safety and Health Act (OSHA) requires where asbestos dust generation is possible to be isolated and posted with warning signs. Only technicians carrying out brake or clutch repair are to be present in the area. Failure to follow these instructions may result in personal injury.
CAUTION: To reduce the possibility of uneven braking, always install new rear brake shoes at both ends of an axle.
1. Remove the tire and wheel assembly.
2. CAUTION: Use of a brake drum puller or a torch is not recommended. Brake drum distortion can result.
NOTE: If the brake drum is rusted to the axle shaft pilot diameter, tap the center of the brake drum between the wheel studs.
Remove the brake drum.
^ If equipped, remove the brake drum retaining clips.
3. If the brake drums will not come off, follow these steps.
(1) Move the brake shoe adjusting lever off the brake adjuster screw.
(2) Loosen the brake shoe adjuster screw nut by adjusting the nut upward.
4. Using the special tool, measure the brake drum inside diameter.
^ Install a new brake drum if the maximum inside diameter exceeds the specification shown on the outside of the brake drum.
Installation
1. NOTE: If adjusting the rear brakes, refer to Brake Shoe Adjustment.
Position the brake drum on the vehicle.
2. WARNING: Whenever a wheel is installed, always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or brake disc that contacts the wheel. Installing wheels without correct metal-to-metal contact at the wheel mounting surfaces can cause the wheel nuts to loosen and the wheel to come off while the vehicle is in motion, causing loss of control. Failure to follow these instructions may result in personal injury.
Clean the wheel hub mounting surface and wheel pilot.
3. Install the tire and wheel assembly.
Brake Shoe: Service and Repair
Brake Shoes
Special Tool(s): Brake Drum Gauge (134-R0191 or equivalent)
Removal and Installation
1. Remove the brake drum.
2. Use the Brake/Clutch/Service Vacuum to remove brake dust and dirt from the brake assemblies.
3. NOTE: If new rear brake shoes and linings are being installed, resurface the brake drums to remove glazing and to ensure an equal friction surface from side-to-side. Resurfacing will also correct out-of-round and bell conditions.
Using the special tool, measure the braking Surface diameter. If the inside diameter measures more than the maximum specification shown on the outside of the brake drum, install a new brake drum.
4. Remove the parking brake cable from the parking brake cable lever.
5. Remove the hold-down clips and pins.
6. Remove the lower spring.
7. Remove the rear brake shoes.
(1) Pull the bottom of the brake shoe forward.
(2) Release the upper return spring.
^ Remove both brake shoes together.
8. Remove the self adjuster lever.
9. Remove the self adjuster and spring assembly.
^ Return the self adjuster to the fully seated position.
10. Remove the parking brake lever.
(1) Remove the horseshoe clip.
(2) Remove the parking brake lever.
11. Inspect the rear brake shoes for minimum thickness above the backing plate, and install new as necessary.
12. To install, reverse the removal procedure.
Brake Pad: Service and Repair
Brake Pads
Removal
WARNING: Asbestos fiber dust may be present on brake and clutch assemblies and is hazardous to health if inhaled.
Brake and clutch assemblies should be cleaned using a vacuum cleaner recommended for use with asbestos fibers such as a brake/clutch/service vacuum. The bag must be labeled per OSHA instructions, sealed, and the trash hauler notified as to the bag's contents.
If a vacuum suitable for asbestos is not available, cleaning should be done wet. If dust generation is still possible, technicians should wear government-approved toxic dust purifying respirators. Failure to follow these instructions may result in personal injury.
1. Remove the wheel and tire assembly.
2. Remove the brake caliper clip.
3. Position the caliper aside.
(1) Remove brake caliper bolt caps and the bolts.
(2) Position the caliper aside and support.
4. Remove the brake pads,
^ Remove the outer brake pad from the anchor.
^ Remove the inner brake pad from the caliper piston.
5. To install, reverse the removal procedure.
To remove the rotor, follow one extra step to remove the caliper anchor plate:
6. Remove the bolts and brake caliper anchor plate.
7. To install, reverse the removal procedure.
Parts | OEM Part | Price (Q1 2009) | |
| Front Pads | YL8Z-2001-BA | 143.50 | |
Labor | |||
Replace | Skill Level | Mfg. Warr. | Std. |
| Front Pads | B | 0.6 | 0.8 |
| Both Front and Rear | |||
| With Rear Drum Brakes | B | 1.2 | 1.6 |
| NOTE | |||
| To R&R Parking Brake Cable, Add | |||
| Right Side | B | 0.0 | 0.3 |
| Left Side | B | 0.0 | 0.4 |
| Both Sides | B | 0.0 | 0.5 |
| To R&R Rotor, Add | |||
| Front | |||
| One Side | B | 0.2 | 0.2 |
| Both Sides | B | 0.3 | 0.4 |
| Rear | |||
| One Side | B | 0.2 | 0.2 |
| Both Sides | B | 0.4 | 0.4 |
| To R&R Caliper, Add | |||
| Each | B | 0.0 | 0.2 |
| To Overhaul Calipers, Add | |||
| Each | B | 0.0 | 0.3 |
| To R&R Brake Hose, Add | |||
| Each | B | 0.0 | 0.1 |
| To Adjust Parking Brake, Add | B | 0.0 | 0.1 |
| To Reface Rotor, Add | |||
| Each | B | 0.0 | 0.4 |
Brake Drum
Special Tool(s): Brake Drum Gauge (134-R0191 or equivalent)
Removal
WARNING: Asbestos fiber dust can be present on brake and clutch assemblies and is hazardous to health if inhaled.
Brake and clutch assemblies must be cleaned using a vacuum cleaner recommended for use with asbestos filters, such as brake/clutch/service vacuum. The bag must be labeled per the Occupational Safety and Health Act (OSHA) instructions, sealed, and the trash hauler notified as to the bag's contents. Failure to follow these instructions may result in personal injury.
WARNING: If a vacuum suitable for asbestos is not available, cleaning must be done wet. If dust generation is still possible, technicians must wear government-approved toxic dust purifying respirators.
The Occupational Safety and Health Act (OSHA) requires where asbestos dust generation is possible to be isolated and posted with warning signs. Only technicians carrying out brake or clutch repair are to be present in the area. Failure to follow these instructions may result in personal injury.
CAUTION: To reduce the possibility of uneven braking, always install new rear brake shoes at both ends of an axle.
1. Remove the tire and wheel assembly.
2. CAUTION: Use of a brake drum puller or a torch is not recommended. Brake drum distortion can result.
NOTE: If the brake drum is rusted to the axle shaft pilot diameter, tap the center of the brake drum between the wheel studs.
Remove the brake drum.
^ If equipped, remove the brake drum retaining clips.
3. If the brake drums will not come off, follow these steps.
(1) Move the brake shoe adjusting lever off the brake adjuster screw.
(2) Loosen the brake shoe adjuster screw nut by adjusting the nut upward.
4. Using the special tool, measure the brake drum inside diameter.
^ Install a new brake drum if the maximum inside diameter exceeds the specification shown on the outside of the brake drum.
Installation
1. NOTE: If adjusting the rear brakes, refer to Brake Shoe Adjustment.
Position the brake drum on the vehicle.
2. WARNING: Whenever a wheel is installed, always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or brake disc that contacts the wheel. Installing wheels without correct metal-to-metal contact at the wheel mounting surfaces can cause the wheel nuts to loosen and the wheel to come off while the vehicle is in motion, causing loss of control. Failure to follow these instructions may result in personal injury.
Clean the wheel hub mounting surface and wheel pilot.
3. Install the tire and wheel assembly.
Parts | OEM Part | Price (Q1 2009) | |
| Rear Brakes | |||
| Drum | 7L8Z-1126-A | 92.98 | |
Labor | |||
Replace | Skill Level | Mfg. Warr. | Std. |
| Rear Brakes | |||
| One Side | B | 0.0 | 0.4 |
| Both Sides | B | 0.0 | 0.6 |
Brake Shoes
Special Tool(s): Brake Drum Gauge (134-R0191 or equivalent)
Removal and Installation
1. Remove the brake drum.
2. Use the Brake/Clutch/Service Vacuum to remove brake dust and dirt from the brake assemblies.
3. NOTE: If new rear brake shoes and linings are being installed, resurface the brake drums to remove glazing and to ensure an equal friction surface from side-to-side. Resurfacing will also correct out-of-round and bell conditions.
Using the special tool, measure the braking Surface diameter. If the inside diameter measures more than the maximum specification shown on the outside of the brake drum, install a new brake drum.
4. Remove the parking brake cable from the parking brake cable lever.
5. Remove the hold-down clips and pins.
6. Remove the lower spring.
7. Remove the rear brake shoes.
(1) Pull the bottom of the brake shoe forward.
(2) Release the upper return spring.
^ Remove both brake shoes together.
8. Remove the self adjuster lever.
9. Remove the self adjuster and spring assembly.
^ Return the self adjuster to the fully seated position.
10. Remove the parking brake lever.
(1) Remove the horseshoe clip.
(2) Remove the parking brake lever.
11. Inspect the rear brake shoes for minimum thickness above the backing plate, and install new as necessary.
12. To install, reverse the removal procedure.
Parts | OEM Part | Price (Q1 2009) | |
| Rear Shoes | 6L8Z-2200-A | 76.45 | |
Labor | |||
Replace | Skill Level | Mfg. Warr. | Std. |
| Both Front and Rear | |||
| With Rear Drum Brakes | B | 1.2 | 1.6 |
| Rear Shoes | B | 0.8 | 1.3 |
| NOTE | |||
| To R&R Parking Brake Cable, Add | |||
| Right Side | B | 0.0 | 0.3 |
| Left Side | B | 0.0 | 0.4 |
| Both Sides | B | 0.0 | 0.5 |
| To Reface Drum, Add | |||
| Each | B | 0.0 | 0.3 |
| To R&R Wheel Cylinder, Add | |||
| Each | B | 0.0 | 0.1 |
| To Overhaul Wheel Cylinder, Add | |||
| Each | B | 0.0 | 0.2 |
| To R&R Brake Hose, Add | |||
| Each | B | 0.0 | 0.1 |
| To Adjust Parking Brake, Add | B | 0.0 | 0.1 |
