NO REAR BRAKES

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.

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.

5.Remove adjuster spring from adjust lever and brake shoe.

6.Remove adjust lever and turn the adjusting wheel of adjuster assembly to the direction of the arrow as shown.

7.Remove the strut spring and the lower retracting spring from the brake shoe.

8.Remove the upper return spring from the brake shoe.

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.

11.Remove the trailing brake shoe from the brake back plate after removing hold down spring and pin.

12.Remove the trailing brake shoe from the rear parking cable.

13.Remove parking pivot lever from the leading brake shoe.

Replacement
1.Lubricate the eight shoe contact areas on the back plate and anchor.

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.

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.

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.

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.

4.Measure the inside diameter of the brake drum.
Standard : 10 in (254 mm)
Maximum : 10.07 in (256 mm)

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.

get a washer welded in its place but if you dont want to go that way you will need to pull the brake shoes the drive axle just to get to the backing plate so you can remove the old one and install a new one

SECTION 206-02: Drum Brake 1999 Cougar Workshop Manual REMOVAL AND INSTALLATION Procedure revision date: 09/14/2001 Brake Shoes Removal

1. Loosen the wheel nuts.

1. Raise and support the vehicle. For additional information, refer to Section 100-02.

1. Remove the wheel.

1. Release the brake shoe automatic adjuster.

1. Remove the brake drum.
   1. Remove the retainers (if equipped).
   1. Remove the drum.

1. Make sure that the hub flange is in the correct position as shown.

1. Remove the hold down springs.

1. Disconnect the parking brake cable.
   1. Lever the secondary shoe outwards.
   1. Disconnect the cable from the secondary shoe.

1. Disconnect the shoes from the anchor block.
   1. Disconnect the shoes from the anchor block.
   1. Remove the lower return spring.

1. CAUTION: Do not damage the wheel cylinder boots.
   Detach the shoes from the wheel cylinder.

1. Hold the wheel cylinder pistons in place with a rubber band.

1. Remove the upper return spring.

1. Remove the primary shoe from the strut and brake shoe adjuster.
   1. Rotate the adjuster counterclockwise.
   1. Remove the primary shoe.

1. CAUTION: Take care as the strut support spring is under tension.
   Detach the secondary shoe from the strut support.
   • Detach the strut from the shoe by levering the strut against the shoe.

1. Remove the parking brake return spring.

Installation
NOTE: Install new shoes as axle sets.

1. Clean, check and apply Silicon Dielectric Compound D742-18A331-A or equivalent meeting Ford specification ESA-M1C171-A to the backing plate contact points.

1. Install the parking brake return spring.

1. Install the secondary shoe to the strut and brake shoe adjuster.

1. Install the primary shoe to the strut and brake shoe adjuster.
   1. Install the primary shoe.
   1. Rotate the adjuster fully clockwise.

1. Install the upper return spring.

1. Remove the rubber band holding the wheel cylinder pistons in place.

1. CAUTION: Do not damage the wheel cylinder boots.
   Position the shoes to the wheel cylinder.

1. Position the shoes to the anchor block.
   1. Install the lower return spring.
   1. Position the shoes to the anchor block.

1. Install the hold down springs.

1. Install the parking brake cable.
   1. Lever the secondary shoe outwards.
   1. Install the cable to the secondary shoe.

1. Install the brake drum.
   1. Install the drum.
   1. Install the retainers (if equipped).

1. Install the wheel.

1. Operate the brake pedal to achieve automatic adjustment.

After you remove the tire, the drim should slide off. If it doesn't then try using a rubber mallet and gently tap on the outside edge as you pull on it. Sometimes you also need to tap on the drum in the center part. I have sprayed penetrating lubes like WD-40 or PB Blaster into the seam at the center. You may also have to back off the parking brake cable or even use the adjuster to back off the shoes.

1989-97 Vehicles Drum Brakes (Let me know if you need the Disc Brake Instructions)

1. Raise and safely support the vehicle.
   
2. Remove the rear wheel and tire assemblies, then remove the brake drum.
   
   
   
   
   
   Fig. 4: View of the drum brake assembly with the drum removed
   
   
   
   
   
   
   Fig. 5: Use a commercially available brake spray to clean the
   components before removal
   
   
   
   
3. Install Brake Cylinder Clamp D81L-1103-B or equivalent, over the ends of the
   rear wheel cylinder.
   
4. Disconnect the parking brake cable from the parking brake lever.
   
   
   
   
   
   Fig. 6: Detach the parking brake cable and conduit from the
   parking brake lever
   
   
   
   
5. Remove the 2 brake shoe hold-down retainers, springs and pins.
   
6. Spread the brake shoes over the piston shoe guide slots. Lift the brake
   shoes, springs and adjuster off the backing plate as an assembly. Be careful not
   to bend the adjusting lever.
   
   
   
   
   
   Fig. 7: Lift the brake shoes, springs and adjuster off the
   backing plate as an assembly
   
   
   
   
7. Remove the adjuster spring. To separate the shoes, remove the retracting
   springs.
   
8. Remove the parking brake lever retaining clip and spring washer. Remove the
   lever from the pin.
   
   
   
   
   
   Fig. 8: Drum brake components - 1995 vehicle shown
   
   
   
   
   
   
   
   Fig. 9: Exploded view of the drum brake components, removed
   from the vehicle
   
   To install:
   
   
9. Apply a light coating of caliper slide grease to the backing plate brake
   shoe contact areas.
   
10. Apply a light coat of lubricant to the threaded areas of the adjuster screw
    and socket. Assemble the brake adjuster with the stainless steel washer. Turn
    the socket all the way down on the screw, then back off 1?2 turn.
    
11. Install the parking brake lever to the trailing shoe with the spring washer
    and a new retaining clip. Crimp the clip to securely retain the lever.
    
12. Position the trailing shoe on the backing plate and attach the parking brake
    cable. Position the leading shoe on the backing plate and attach the lower
    retracting spring to the brake shoes.
    
13. Install the adjuster assembly to the slots in the brake shoes. The socket
    end must fit into the wider slot in the leading shoe. The slot in the adjuster
    nut must fit into the slots in the trailing shoe and parking brake lever.
    
    
    
    
    
    Fig. 10: Install the adjuster assembly in the slots in the
    brake shoes
    
    
    
    
    
14. Install the adjuster lever on the pin on the leading shoe and to the slot in
    the adjuster socket.
    
15. Install the upper retracting spring in the slot on the trailing shoe and the
    slot in the adjuster lever. The adjuster lever should contact the star and
    adjuster assembly.
    
16. Install the brake shoe anchor pins, springs and retainers. Remove the brake
    cylinder clamp tool
    
17. Install the brake drum, wheel and tire assemblies and lower the vehicle.
    
18. Apply the brakes several times while backing up the vehicle. After each
    stop, the vehicle must be moved forward.
    
    

First you have to compress the parking brake cable spring and attach the parking brake lever.
Clean and lubricate the brake backing plate.
Use silicon Brake Caliper Grease and Dielectric Compound.
Then,
install the rear brake shoes and linings:
1) position the rear brake shoes and linings
2) position the parking brake lever
3) install the brake shoe hold-down spring pins and the brake shoe hold-down springs.

Install the parking brake strut
1. install the parkig brake link spring on the parking brake strut
2. install the parking brake strut
3. Install the brake shoe anchor ping guide plate.

Install the short brake shoe retracting spring
1. Place the brake shoe adjusting lever cable over the anchor pin, with crimped side in
2. Install the short brake shoe retracting spring

Note: Make sure the brake shoe adjusting lever cable is positioned in the cable guide groove

Install the long brake shoe retracting
1. install the cable guide
2. position the brake shoe adjusting lever cable in the cable guide groove
3. install the long brake shoe retracting spring

Note: to prevent incorrect installation, teh socket of each brake adjuster screw is stamped R or L

Assemble the brake adjuster screw assembly.
1. apply silicone brake caliper grease and dielectric compound
2. install the brake adjuster screw into the brake show adjusting screw nut to the end of the threads and then loosen one half turn
3. install the brake shoe adjusting screw socket on the brake shoe adjusting screw nut.

Install the brake adjuster screw assembly
1. Position the brake adjuster screw assembly
2. Install the brake shoe adjusting screw spring
3. Position the brake shoe adjusting lever cable
4. Position the adjusting lever return spring and the brake shoe adjusting lever
5. Hook the brake shoe adjusting lever cable to the brake shoe adjusting lever.

Test the operation of the automatic self-adjuster
1. Pull the brake shoe adjusting lever cable and check that the brake shoe adjusting lever rotates the brake shoe adjuster assembly
2. Release the brake shoe adjusting lever cable and check that the brake shoe adjusting lever advances to the next notch on the brake shoe adjusting screw nut.

Adjust the brakes.

Install the brake drum.

Thats it

If the following is not enough then maybe try Alldata.com which generally has more information, but it will cost: REMOVAL & INSTALLATION Chrysler Concorde, New Yorker, LHS Dodge Intrepid Eagle Vision

1. Remove the rear wheels and brake drums.
2. Remove the dust cap from the rear hub and bearing assembly.
3. Remove the cotter pin, nut retainer and wave washer. Discard the old cotter pin.
4. Remove the rear hub and bearing assembly retainer nut and washer. Remove the rear hub and bearing assembly from the spindle.
5. Remove the automatic adjuster spring from the adjuster lever.
6. Rotate the automatic adjuster starwheel enough so both shoes move out far enough to be free of the wheel cylinder boots.
7. Disconnect the parking brake cable from the actuating lever. Disconnect parking brake cable one side at a time.
8. Remove the both lower brake shoe to anchor springs.
9. Remove the 2 brake shoe hold-down springs from the brake shoes.
10. Remove the brake shoes, upper shoe-to-shoe return spring, automatic adjuster and automatic adjuster lever from the backing plate as an assembly.
11. Separate the brake shoes from the automatic adjuster mechanism.
12. Remove the brake shoe automatic adjuster lever from the leading brake shoe. To install:
    
13. Thoroughly clean and dry the backing plate. To prepare the backing plate, lubricate the bosses, anchor pin and parking brake actuating lever pivot surface lightly with lithium based grease.
14. Remove, clean and dry all parts still on the old shoes. Lubricate the starwheel shaft threads with anti-seize lubricant.
15. Assemble both brake shoes, the top shoe to shoe return spring, automatic adjuster and automatic adjuster lever before mounting on vehicle. Make sure the ends of the automatic adjusters are positioned above the extruded pins in the webbing of the brake shoes prior to installation.
16. Install the brake shoe assembly onto the brake support plate and install the hold-down springs.
17. Install the lower anchor springs and reconnect the parking brake cable to the park brake lever of the trailing brake shoe.
18. Rotate the serrated adjuster nut to remove the free-play from the adjuster assembly.
19. Install the automatic adjuster lever spring on the lead brake shoe assembly and the automatic adjuster lever.
20. Install the rear hub and bearing assembly. Install washer and retainer nut and torque to 124 ft. lbs. (168 Nm).
21. Install the wave washer, nut retainer and a new cotter pin onto the spindle. Install dust cap.
22. Adjust brake shoes so not to interfere with brake drum installation. Install the rear brake drum. NOTE: After installing the brake drums, pump the brake pedal several times to partially adjust the brake shoes. To verify proper operation of the self-adjusting parking brake, be sure that both rear brakes are not dragging when the parking brake pedal is released.
    
23. Install the rear wheels and lug nuts. Torque the lug nuts, in a star pattern sequence, to 95 ft. lbs. (129 Nm).
24. Road test the vehicle. The automatic adjusters will continue brake adjustment during the road test of the vehicle.

Brake Shoes Removal & Installation To Remove:

1. Raise and safely support rear of vehicle.
2. Remove rear wheel assemblies.
3. Release parking brake.
4. Remove brake drum.

Rear brake shoe assembly

1. Using an appropriate brake spring tool, unhook upper return spring from rearward brake shoe.
2. Push retainer springs IN and turn to remove tension pins.
3. Lower brake shoe assembly and remove lower return spring.
4. Remove brake shoe assembly from back plate.
5. Disconnect parking brake cable from lever and remove brake shoe.
6. Remove parking brake lever from brake shoe.

To Install:

1. Install parking brake lever to rearward brake shoe.
2. Secure lever to brake show with a NEW U-clip.
3. Pinch U-clip closed.
4. Connect parking brake cable to rearward brake shoe.
5. Install self-adjuster lever spring on front brake shoe.
6. Assemble clevises, adjuster bolt and upper and lower return springs.
7. Apply a light coat of grease (Molykote 44MA or equivalent) to sliding surfaces.
8. Install brake shoe assembly onto back plate.
9. Install tension springs.
10. Using an appropriate brake spring tool, unhook upper return spring to rearward brake shoe.
11. Install brake drum.
12. Install rear wheel assembly.
13. Lower vehicle.
14. Adjust self-adjusting brakes by pressing brake pedal several times.

Removal Procedure Tools RequiredJ 38400
Caution: Keep fingers away from rear brake shoe springs to prevent fingers from being pinched between spring and shoe web or spring and backing plate.

1. Remove the brake drum. Refer to Brake Drum Replacement



Notice: Do not over stretch the adjuster spring. Damage can occur if the spring is over stretched.

2. Use the J 38400 in order remove the adjuster spring (1). Disengage the adjuster spring loop from the tab on the adjuster actuator.
2.1. Remove the loop end of the adjuster spring from the adjuster actuator. 2.2. Remove the straight end of the adjuster spring from the secondary brake shoe.



3. Use the J 38400 in order to spread the brake shoes apart.
4. Remove the adjuster.

Installation Procedure

1. Use the J 38400 in order to spread the brake shoes apart.



Important: Ensure that the adjuster (2) engages the brake shoes (4 and 5), the park brake actuator (3), and the adjuster actuator (1) properly.

2. Install the adjuster.



Notice: Do not over stretch the adjuster spring. Damage can occur if the spring is over stretched.

3. Install the adjuster spring (1).
3.1. Install the straight end of the adjuster spring into the secondary brake shoe. 3.2. Install the loop end of the adjuster spring to the adjuster actuator.
4. Install the brake drum.