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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  • Suzuki Master
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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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I have a 23 t bucket and i cant get a brake pedal.when i bought it had very little brake so i replaced rear shoes and cylinders,front pads and calipers,all new lines and the master cylinder


Once you have bled the air from the brake lines,clamp off the front brake hoses carefully.Does the pedal feel better now?
Then the pad /caliper fit is allowing too much play.Is the pedal the same?Then clamp the rear hose and try the pedal.Is it fine with the rear hose clamped?If so we now know the problem is at the rear brakes.One common low pedal rear brake cause is brake shoes that do not fit the drums.Remove the drums and look at the shoes,are they showing contact wear fully or just in the middle of the shoe?Remove a shoe and place it in the drum.Can you rock the shoe against the drum surface?Once drums have been resurfaced,the shoes will not fit fully against the drum allowing the shoe the flex when applying pressure to it and this can easily create a low soft brake pedal. Of course rear brake adjustment must be correct once brake shoe contact is correct.To correct brake shoe contact,have your shoes re arc-ed to fit resurfaced drums or install new drums.Don't overlook brake master cyl /brake pedal push rod adjustment too.

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The brake drum does not fit due to the pressure in brake cylinders. Some of the cylinders are designed to keep a little pressure on, even when the pedal is released. The reason is that you will have instant reaction on pushing break pedal because there is no free space between drum and pads. You need to take clamp and push the pistons back in cylinder, but only that much so you can fit the drum. After the drum is tightened you must pump the brake pedal until you can fell that there is no free fall. The hand brake should be ok, but check it just to be shore. If there is need to tension the cable, it can be done under lever from outside the car (you must go under the car).

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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.
bj6c017e.gif
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)
bj6c017l.gif
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.
bj6c017m.gif

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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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    Fig. 10: Install the adjuster assembly in the slots in the
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    88189g33.gif



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1 Answer

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make sure the brake shoe fits in the drum and is seated tip to tip and you can push it all the way around the inside of the drum.
then install the shoes.
and then trun the adjuster screw all theway in to colapse the shoes in all theway.then the drum will fit.
the adjust the adjuster screw back out untill it just begins to rub on the drum.not tight at all just enough to rub very lightly.
after a few miles you may have to go back to the rear brakes and adjust them a little more.
proper adjustment in the rear shoes is important to a good strong pedal.

hope this helps
thank you
jm

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