Question about 2003 Suzuki Aerio

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Rear drum installation

I just replaced the shoes on my rear brakes and cant get the drums to fit back over the shoes, any ideas what i can do?

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The new shoes are thicker than the old ones. You need to turn the adjuster in "till you get proper clearance. Self adjuster screw is often frozen... if so, use a good solvent and coat threads with white grease before re-using. Once you do this, the drum will go back on. Heres a tip: use a round file or 60grit sandpaper to knock down the rusted lip on the inside leading edge of the drum (the edge that is closest to the backing plate when installed) This edge is cut off when machining the drum, most people working at home don't have drums cut and therefore run into this problem. Don't adjust too tight, or you will burn the new linings. Allow the self adjusters to take up the slack.
Good luck

Posted on Jan 01, 2009

  • Richard Scordino Jan 01, 2009

    The new shoes are thicker than the old ones. You need to turn the adjuster in "till you get proper clearance. Self adjuster screw is often frozen... if so, use a good solvent and coat threads with white grease before re-using. Once you do this, the drum will go back on. Heres a tip: use a round file or 60grit sandpaper to knock down the rusted lip on the inside leading edge of the drum (the edge that is closest to the backing plate when installed) This edge is cut off when machining the drum, most people working at home don't have drums cut and therefore run into this problem. Don't adjust too tight, or you will burn the new linings. Allow the self adjusters to take up the slack.
    Good luck

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Adjusting Kia rio handbrake cable


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Removal
1.Remove rear wheel and tire assembly from vehicle.

2.Remove rear brake drums from hub and bearing assemblies after loosening the two brake drum screws.
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3.Be sure that the parking brake pedal is in the release(most upward) position.

4.Completely loosen square nut of the rear parking brake cable. Then create slack in the rear parking brake cables.
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5.Remove adjuster spring from adjust lever and brake shoe.
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6.Remove adjust lever and turn the adjusting wheel of adjuster assembly to the direction of the arrow as shown.
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7.Remove the strut spring and the lower retracting spring from the brake shoe.
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8.Remove the upper return spring from the brake shoe.
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9.Remove brake back plate hold down spring and pin from the leading brake shoe assembly.

10.Remove the leading brake shoe. Then remove the adjuster assembly, strut and anchor spring from the trailing brake shoe.
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11.Remove the trailing brake shoe from the brake back plate after removing hold down spring and pin.
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12.Remove the trailing brake shoe from the rear parking cable.
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13.Remove parking pivot lever from the leading brake shoe.
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Replacement
1.Lubricate the eight shoe contact areas on the back plate and anchor.
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2.Install the trailing brake shoe to the rear parking cable.

3.Install trailing brake shoe on brake back plate and install the trailing brake shoe hold down spring and pin on the brake shoe.

4.Tighten the square nut of rear parking cable.

5.Install the anchor spring then install adjuster assembly, and strut.

6.Install leading brake shoe on brake back plate.
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7.Install the brake shoe upper return spring, strut spring and the lower retracting spring to the brake shoe.

8.Properly rotate the adjusting wheel of adjuster assembly to the direction of the arrow in as shown.
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9.Install the adjuster spring on the adjust lever and leading brake shoe assembly.

10.Install the leading brake shoe hold down spring and pin on the brake shoe.
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11.Adjust brake shoes assemblies so as not to interfere with brake drum installation.

12.Install the rear brake drums on the hubs.

13.Check and adjust whether the pedal stroke in the specification.(Refer to section BR Gr./On-vehicle service/Pedal stroke of parking brake)

14.Install wheel and tire.

15.Push the parking brake pedal to the floor once and release pedal. This will automatically remove the slack from and correctly adjust the parking brake cables.

16.Test the vehiche on the road. The adjust will continue the brake adjustment during the road test of vehicle.

Inspection
1.Inspect the disassembled parts for wear, rust or damage.

2.Measure the thickness of brake shoe lining.
Standard : 0.17 in (4.5 mm)
Minimum : 0.04 in (1 mm)

3.If the shoe lining is less than minimum or shows signs of uneven wear, replace new one.
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4.Measure the inside diameter of the brake drum.
Standard : 10 in (254 mm)
Maximum : 10.07 in (256 mm)
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5.If the inside diameter of the brake drum is more than maximum or shows signs of uneven wear, replace new one.

6.Inspect the lining and drum for proper contact. If the contact condition is improper, repair it with a grinder or replace the brake shoe assembly.
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Replacing rear brakes



REMOVAL & INSTALLATION
It is a good idea to only disassemble and assemble one side at a time, leaving the other side intact as a reference.

  1. Raise and support the vehicle safely.
  2. Remove the brake drum.
  3. Disconnect the parking brake rear cable and conduit.
  4. Remove the brake shoe hold-down springs and brake shoe hold-down pins.
  5. Remove the brake shoe adjusting screw spring.
  6. Remove the brake shoe adjusting lever and adjuster screw.
  7. Remove the brake shoe retracting spring.
  8. Remove the brake shoes from the backing plate.
  9. Remove and discard the parking brake lever clip. Remove the washer.
  10. Remove the parking brake lever from the rear brake shoe.

To install:
  1. Thoroughly clean the backing plate with brake cleaning solvent and dry completely.
  2. Use silicone grease to lubricate the brake backing plate-to-brake shoe contact areas.
  3. Apply a light coating of premium grease to the threaded areas of the adjuster. Turn the adjuster in and out to spread the lubricant. Turn the adjuster all the way down on the screw and loosen one-half turn.
  4. Install the parking brake lever to the rear (secondary) brake shoe with a new clip.
  5. Position the brake shoes on the backing plate and install the brake shoe hold-down springs.
  6. Attach the parking brake rear cable and conduit to the parking brake lever.
  7. Attach the brake shoe retracting spring.

The socket end of the brake adjuster screw is stamped with "R" or "L" to indicate that it is to be installed either on the right (passenger's side) or left (driver's side) of the vehicle. The adjuster nuts can be distinguished by the number of grooves machined around the body of the nut. Two grooves indicate a right-hand adjuster nut and one groove indicates a left-hand adjuster nut. Another way to identify brake adjuster assemblies is to check thread pitch. The right side adjuster assembly has right-hand threads and the left side has left-hand threads. If installed correctly, the brake adjuster assembly will increase in length when the brake shoe adjusting lever is operated.
  1. Install brake adjuster screw in the slots on the brake shoes. The wider slot on the socket end must fit in the slot on the front (primary) brake shoe.
  2. Install the brake shoe adjusting lever on the lever pin.
  3. Install the brake adjusting screw in the slot on the secondary brake shoe and in the slot on the brake shoe lever. The brake shoe adjusting lever should contact the brake adjuster screw.
  4. Adjust the brake shoes.
  5. Install the drums.


ADJUSTMENTS

The drum brakes are self-adjusting and require a manual adjustment only after the brake shoes have been replaced, or when the length of the adjusting screw has been changed while performing some other service operation.
Drum Installed

  1. Raise and support the vehicle safely.
  2. Remove the rubber plug from the adjusting slot on the backing plate.
  3. Insert a Brake Adjustment Tool (D81L-1103-C) or equivalent into the slot and engage the lowest possible tooth on the starwheel. Move the end of the brake spoon downward to move the starwheel upward and expand the adjusting screw. Repeat this operation until the brakes lock the wheels.
  4. Insert a small screwdriver or piece of firm wire (coat hanger wire) into the adjusting slot and push the automatic adjusting lever out and free of the starwheel on the adjusting screw and hold it there.
  5. Engage the topmost tooth possible on the starwheel with the brake adjusting spoon. Move the end of the adjusting spoon upward to move the adjusting screw starwheel downward and contract the adjusting screw. Back off the adjusting screw starwheel until the wheel spins freely with a minimum of drag. Keep track of the number of turns that the starwheel is backed off, or the number of strokes taken with the brake adjusting spoon.
  6. Repeat this operation for the other side. When backing off the brakes on the other side, the starwheel adjuster must be backed off the same number of turns to prevent side-to-side brake pull.
  7. When the brakes are adjusted, make several stops while backing the vehicle to equalize the brakes on both of the wheels.
  8. Lower the vehicle.

Drum Removed
See Figure 2


0900c152800ae432.jpg enlarge_icon.gifenlarge_tooltip.gif

Fig. Fig. 2: When using a brake adjustment gauge, first measure the inside diameter of the drum (top) and then adjust the brakes shoes to the proper outside diameter (bottom)

  1. Remove the brake drum.
  2. Make sure that the shoe-to-contact pad areas are clean and properly lubricated.
  3. Using a Brake Adjustment Gauge (D81L-1103-A) or equivalent, check the inside diameter of the drum.
  4. Measure across the diameter of the assembled brake shoes, at their widest point.
  5. Turn the adjusting screw so that the diameter of the shoes is 0.030 in. (0.76mm) less than the brake drum inner diameter.
  6. Install the drum.


INSPECTION

See Figure 3


0900c152800ae433.jpg enlarge_icon.gifenlarge_tooltip.gif

Fig. Fig. 3: Measure brake shoe thickness in several places around the shoe
Inspect the brake shoes for wear using a ruler or Vernier caliper. Compare measurements to the brake specifications chart. If the lining is thinner than specification or there is evidence of the lining being contaminated by brake fluid or oil, replace all brake pad assemblies (a complete axle set).

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1 Answer

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    Fig. 4: View of the drum brake assembly with the drum removed
    88189p14.jpg





    Fig. 5: Use a commercially available brake spray to clean the
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    88189p15.jpg


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    Fig. 6: Detach the parking brake cable and conduit from the
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    88189g31.gif


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    Fig. 7: Lift the brake shoes, springs and adjuster off the
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    88189p16.jpg


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    Fig. 8: Drum brake components - 1995 vehicle shown
    88189g32.gif






    Fig. 9: Exploded view of the drum brake components, removed
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    88189p17.jpg
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  10. Apply a light coat of lubricant to the threaded areas of the adjuster screw
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    Fig. 10: Install the adjuster assembly in the slots in the
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    88189g33.gif



  14. Install the adjuster lever on the pin on the leading shoe and to the slot in
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  1. Raise and safely support the vehicle.
  2. Remove the rear wheels.
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1 Answer

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