AutoZone 2002 Ford Escort ZX2 2.0L MFI DOHC 4cyl | Repair Guides | Brakes | Rear Drum Brakes | Brake Shoes | AutoZone.com

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    2002 Ford Escort ZX2 2.0L MFI DOHC 4cyl

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    HHR 2006-2008

    Brake Shoes

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    Adjustment



    1. Before servicing the vehicle, refer to the Precautions Section.
    2.  
    3. Ensure that the park brake lever is in the fully released position.
    4.  
    5. Release the park brake lever boot from the floor console by applying light pressure inward on the sides of the boot retainer.
    6.  
    7. Pull the boot away from the console to expose the front park brake cable adjusting nut.
    8.  
    9. Release the tension from the park brake cable system at the front cable adjusting nut. Using ONLY HAND TOOLS, loosen the adjusting nut completely to the end of the front cable threaded rod.
    10.  
    11. Raise and support the vehicle.
    12.  
    13. Remove the rear tire and wheel assemblies.

      Click image to see an enlarged view

      Fig. Measuring the drum inner diameter

    14.  
    15. Remove the brake drums.
    16.  
    17. Measure the inner diameter of the drum with a caliper such as tool J 21177-A at its widest point.
    18.  
    19. Firmly hand tighten the set screw on the tool.
    20.  
    21. Remove the tool from the brake drum and position it over the corresponding brake shoe assembly at its widest point.
    22.  
    23. While holding the tool in position, insert a 0.025 inch (0.635mm) feeler gage between one side of the tool, and the corresponding brake shoe lining.
    24.  
    25. Rotate the brake shoe adjuster screw until the brake shoe linings contact the tool, and the feeler gage.
    26.  
    27. Repeat the above steps for the opposite brake drum and brake shoe assembly.
    28.  
    29. Install the brake drums.
    30.  
    31. Adjust the park brake.
    32.  
    33. Install the rear tire and wheel assemblies.
    34.  
    35. Lower the vehicle.
    36.  
    37. Position the park brake lever boot to the floor console and press the boot retainer into place to secure.
    38.  

    Removal & Installation



    1. Before servicing the vehicle, refer to the Precautions Section.
    2.  
    3. Raise and support the vehicle.
    4.  
    5. Remove the tire and wheel assembly.
    6.  
    7. Remove the brake drum.
      WARNING
      Do not over stretch the adjuster spring. Damage can occur if the spring is over stretched.



      Click image to see an enlarged view

      Fig. Adjuster spring (1)

    8.  
    9. Remove the adjuster spring. Disengage the adjuster spring hook end from the tab on the adjuster actuator lever, then release the spring from the brake shoe web hole.

      Click image to see an enlarged view

      Fig. Adjuster lever (1)

    10.  
    11. Remove the adjuster actuator lever (1) from the pivot.

      Click image to see an enlarged view

      Fig. Using brake tool J 38400 (1), or equivalent, spread the top of the brake shoes apart

    12.  
    13. Using brake tool J 38400 (1), or equivalent, spread the top of the brake shoes apart.
    14.  
    15. Remove the adjuster assembly (2) from the brake shoes.

      Click image to see an enlarged view

      Fig. Position the hook end of the tool under the universal spring and lightly pull the universal spring end out of the shoe web hole

    16.  
    17. Position the hook end of the tool under the universal spring and lightly pull the universal spring end out of the shoe web hole. Hold the universal spring while removing the trailing brake shoe.
    18.  
    19. Release the park brake cable from the park brake lever on the trailing shoe.

      Click image to see an enlarged view

      Fig. Position the hook end of the tool under the universal spring and lightly pull the universal spring end out of the shoe web hole

    20.  
    21. Position the hook end of the tool under the universal spring and lightly pull the universal spring end out of the shoe web hole. Hold the universal spring while removing the leading brake shoe.
    22.  

    To install:

    1. Measure the brake shoe lining thickness. Brake shoe lining minimum thickness is 0.020 inch (0.5mm).
    2.  
    3. If the brake shoe lining thickness is at or below the minimum specification, replace the brake shoes.
    4.  
    5. Apply a thin, light coat of high temperature silicone brake lubricant to the brake shoe contact surfaces of the brake backing plate.
    6.  
    7. Position the hook end of the tool under the universal spring and lightly pull the universal spring end out while installing the leading brake shoe. Ensure that the universal spring engages the brake shoe web hole.
    8.  
    9. Install the park brake cable to the park brake lever on the trailing brake shoe.
    10.  
    11. Position the hook end of the tool under the universal spring and lightly pull the universal spring end out while installing the trailing brake shoe. Ensure that the universal spring properly engages the brake shoe web hole.
    12.  
    13. Using the tool, spread the top of the brake shoes apart.
    14.  
    15. Install the adjuster assembly to the brake shoes.
    16.  
    17. Install the adjuster actuator lever to the brake shoe and the adjuster assembly. Ensure that the lever is properly engaged between the adjuster assembly and the brake shoe.
      WARNING
      Do not over stretch the adjuster spring. Damage can occur if the spring is over stretched.

    18.  
    19. Install the adjuster spring. Ensure that the loop end of the spring fully engages the tab on the actuator lever.
    20.  
    21. Adjust the drum brakes.
    22.  
    23. Install the brake drum.
    24.  
    25. Install the tire and wheel assembly.
    26.  
    27. Lower the vehicle.
    28.  

     
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