To adjust back brakes - 1999 Chevrolet Malibu

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.

For starters, set the cable adjustment back to the original setting. We in the States have something similiar called an Hombre. Follow the instructions for adjustings the rear brakes FIRST. Once these have been adjusted, if the brake will still not hold, then and only then, adjust the cable setting a couple of turns at a time until at least 3 - 5 clicks are achieved when setting the parking/emergency (depending on where you are in the world) brake. Let me know if you need anything further.

REAR DRUM BRAKES


See Figure 1
Normal adjustments of the rear drum brakes are automatic and are made during the reverse applications of the brakes. The following procedure should be used ONLY if the linings have been replaced.

Fig. Fig. 1: Drum brake adjustment

1. Raise and support the rear of the vehicle safely using jackstands.
2. Using a punch and a hammer on the rear of the backing plates, knock out the lanced metal areas near the starwheel assemblies on each plate. The metal areas may already have been removed and covered with rubber adjustment plugs, if so remove the plugs by grasping and pulling with a pair of pliers.

After knocking out the lanced metal areas from the backing plate, the wheels must be removed and all of the metal pieces discarded, then the wheels should be reinstalled for adjustment.

1. Insert a suitable brake adjustment tool such as J-4735 or equivalent, into the breaking plate slots and engage the lowest possible tooth on the starwheel. Move the end of the brake tool downward to move the starwheel upward and expand the adjusting screw. Repeat this operation until the wheels can JUST be turned by hand. This is a position immediately before the brakes lock.

The brake drag should be equal at both wheels.

1. Back off the adjusting screws 24 notches (clicks). By the time you have backed off the adjustment 12 clicks, the brakes should have no drag. If a heavy drag is still present, the parking brake cable is likely in need of adjustment.
2. Make sure both sides of the brakes are properly adjusted. When backing off the brakes on the other side, the adjusting lever must be backed off the same number of turns to prevent side-to-side brake pull.
3. After the brakes are adjusted, install a rubber hole cover into each of the backing plate slots. To complete the brake adjustment operation, make several stops while backing the vehicle to fully equalize the adjustment.
4. Road test the vehicle.

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

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

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).

Try to adjust the rear brakes tighter at the shoes, if you have drum brakes. May require taking the drum off and adjusting the adjuster. Or, adjusting it from the backing plate access hole if there is one.

Be sure to check the cables to make sure they are not broken anywhere between the hand brake lever and the back brakes.

Good luck on this repair.

ADJUSTMENT

1. Raise and safely support the vehicle.
   
2. Remove the wheel and tire assembly.
   
3. Remove the brake drum.
   
4. Using a brake adjusting gauge, measure the inside diameter of the brake
   drum.
   
5. Compare the brake drum measurement to the brake shoes.
   
6. Adjust the brake shoes by inserting a brake adjustment tool into the knurled
   quadrant of the rear quad operating lever and adjust the shoes to the same
   measurement as the brake drum.
   
7. Install the brake drum.
   
8. Install the wheel and tire assembly.
   
9. Lower the vehicle.
   
10. Check the brake system operation by making several stops while driving
    slowly forward.

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

Brake Shoes REMOVAL & INSTALLATION Fig. 1: Use a brake cleaner to clean the brake surfaces
Fig. 2: Using a brake tool, remove the return spring from the anchor pin
Fig. 3: Remove the return spring and the adjuster cable guide
Fig. 4: Remove the adjuster cable
Fig. 5: Remove the shoe guide plate
Fig. 6: Disengage the hold-down spring retainers from the hold-down pins
Fig. 7: Remove the hold-down springs and pins
Fig. 8: Pull the shoes apart and then . . .
Fig. 9: . . . remove the parking brake strut and spring
Fig. 10: Remove the shoes from the backing plate
Fig. 11: Disengage the parking brake cable
Fig. 12: Lubricate the shoe contact points — 10 inch drum brake backing plate shown
Fig. 13: Adjusting the gauge to fit the brake drum
Fig. 14: Adjust the brake shoes to fit the gauge
Fig. 15: Adjusting the drum brakes using a brake spoon
CAUTION
Brake shoes may contain asbestos, which has been determined to be a cancer causing agent. Never clean the brake surfaces with compressed air! Avoid inhaling any dust from any brake surface! When cleaning brake surfaces, use a commercially available brake cleaning fluid. NOTE: A brake spring removal tool and a brake adjusting gauge are required for this procedure.

1. Raise and support the vehicle safely with jackstands.
2. If the brakes have never been serviced before, the drums will be held on the wheel studs with spring nuts. Remove the spring nuts and discard.
3. Turn the adjustment starwheel so that the brake shoes are retracted from the brake drum and remove the brake drum.
4. Install wheel cylinder clamps to retain the wheel cylinder pistons in place and prevent leakage of brake fluid while replacing the shoes.
5. Remove the U-clip and washer securing the adjuster cable to the parking brake lever.
6. Remove the adjuster cable, cable guide, adjuster lever and adjuster springs. Remove the return springs with a brake spring remover tool.
7. Remove the hold-down retainers and springs, then remove the brake shoes. To install:
   
8. Clean the backing plate with a brush or cloth. Place a dab of Lubriplate® on each spot where the brake shoes rub on the backing plate. NOTE: Always replace brake linings in axle sets. Never replace linings on one side or just on one wheel.
   
9. Thoroughly clean and lubricate the adjuster cable guides, adjuster screw and pivot, parking brake lever and lever pivot pin with multi-purpose grease.
10. Apply a thin coat of multi-purpose chassis lube to the mounting pads on the backing plate.
11. Transfer the parking brake actuating lever to the new secondary shoe.
12. Position the brake shoes on the backing plate, then install the hold-down springs and retainers. Don't forget to engage the parking brake lever with the cable.
13. Install the parking brake actuating bar and spring between the parking brake lever and primary shoe.
14. Install the self-adjusting cable, cable guide and upper return springs.
15. Thoroughly clean the starwheel and lightly lubricate the threads with lithium based grease.
16. Install the starwheel.
17. Install the self-adjusting cam and lower spring. A big pair of locking pliers is good for this job.
18. Check the surface of the brake shoes for any grease that may have gotten on them. If dirty, lightly clean with a piece of sandpaper.
19. Adjust the brakes, install the brake drum and wheel. Lower the vehicle and test drive.

Get a brake shoe adjusting tool at any auto parts store to retract the shoes back to a smaller diameter to release the pressure on the brake drum for removal

You are correct,the brakes are designed to self adjust when you back up, but this is After they have initially been adjusted after a brake job. You say you had to loosen the adjustment some to get the drums back on, this is normal, as the new brake shoes are thicker than the old worn ones. You are not wrong when you thought backing up the truck (and then applying the brakes) will adjust them. What is wrong with this though, is that you would probably have to back up and hit the brakes for a couple of hours if they are in need of quite a bit of adjustment, and that's if the adjusters are working perfectly. You really need to do an initial adjustment while the truck is still jacked up. The rubber grommets should be removed so you can adjust the brakes. It may be difficult to see the adjusters, but that's how you get to them. Do you have a brake adjusting tool? The slight bend in it makes it perfect for getting in the slot. Did you make sure the adjusting wheel is not seized up(or difficult to turn) while you had it apart? To adjust them just right, you can have the wheels on, truck jacked up, adjust and slowly spin the wheel. When you feel a very slight drag, it's adjusted properly. If you over adjust, you need to put a very thin screwdriver through the backing plate and hold the small metal piece that touches the adjusting wheel out and away from the wheel so you can back off on the adjustment. (this small plate is there to prevent the adjuster from loosening by only allowing it to turn in one direction, pushing the plate out of the way allows you to go in the opposite direction, to loosen the brake adjustment).

the brake shoes are likely stuck in the grooves worn into the drum. You need to back off the brake shoe adjusting wheel to loosen the brake shoes.
Also, the face of the drum usually has a couple of threaded holes you can screw bolts into to help pull the drums toward you.

First, hit all the way around the brake drum with a big hammer to loosen the drum from the center hub.
Then, istall the screws to help pull the drum.

to back off the adjuster with a screwdriver:

1. NOTE: If the brake drum will not come off, follow these steps.
2. Loosen the brake shoe adjusting screw nut (2047).
3. Using a screwdriver, move the brake shoe adjusting lever (2A176) off the brake adjuster screw (2041).
4. NOTE: Move the adjustment tool handle downward to loosen the brake shoe adjusting screw nut.
   Use the Brake Adjustment Tool to loosen the brake shoe adjusting screw nut.

please give a good rating if this helps.