Cavalier, Sunfire 2001-2005

Brake Shoes

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Removal & Installation




CAUTION
Dust and dirt accumulating on brake parts during normal use may contain asbestos fibers from production or aftermarket brake linings. Breathing excessive concentrations of asbestos fibers can cause serious bodily harm. Exercise care when servicing brake parts. Do not sand or grind brake lining unless equipment used is designed to contain the dust residue. Do not clean brake parts with compressed air or by dry brushing. Cleaning should be done by dampening the brake components with a fine mist of water, then wiping the brake components clean with a dampened cloth. Dispose of cloth and all residue containing asbestos fibers in an impermeable container with the appropriate label. Follow practices prescribed by the Occupational Safety and Health Administration (OSHA) and the Environmental Protection Agency (EPA) for the handling, processing, and disposing of dust or debris that may contain asbestos fibers.

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove the tire and wheel assembly.
  4.  
  5. Remove the brake drum. It may be necessary to gently tap the rear edge of the drum to start it off the studs. If extreme resistance to removal is encountered, it will be necessary to retract the brake shoe self-adjuster screw, sometime called the starwheel. Turn the adjuster to retract the linings from the drum.
    NOTE
    Do not hammer on the brake drum to remove it.

  6.  
  7. Remove the upper return springs from the shoes using tool J-8057 brake spring tool.
  8.  
  9. Remove the hold-down springs using J-8049 brake spring tool.
  10.  
  11. Remove the shoe hold-down pins from behind the brake backing plate.
  12.  
  13. Lift up the actuator lever for the self-adjusting mechanism and remove the actuating link. Remove the actuator lever, pivot, and the pivot return spring.
  14.  
  15. Spread the shoes apart to clear the wheel cylinder pistons, then remove the parking brake strut and spring.
  16.  
  17. Disconnect the parking brake cable from the lever. Remove the shoes, still connected by their adjusting screw spring.
  18.  
  19. With the shoes removed, note the position of the adjusting spring and remove the spring and adjusting screw.
  20.  
  21. Remove the C-clip from the parking brake lever and remove the lever from the secondary shoe.
  22.  
  23. Use a damp cloth to remove all dirt and dust from the backing plate and brake parts.
  24.  

To install:

  1. Check the backing plate attaching bolts to make sure they are tight. Use fine emery cloth to clean all rust and dirt from the shoe contact surfaces on the plate and lubricate with brake grease. Check the wheel cylinder for signs of leakage.

    Click image to see an enlarged view

    Fig. Exploded view of drum brake components-2002 models

  2.  
  3. Clean all parts completely in brake solvent and air dry.
  4.  
  5. Clean the backing plate shoe contact points.
  6.  
  7. Inspect the inside of the brake drum. If worn, heavily grooved or if the opening is distorted, the drum should be refinished or replaced.
  8.  
  9. Inspect the brake shoe springs and self-adjuster mechanism. Disassemble the adjuster mechanism and clean the threads and coat with grease. Make sure the adjuster assembly turns freely before installing in the vehicle.
  10.  
  11. Install the parking brake lever on the secondary shoe and secure with C-clip.
  12.  
  13. Install the adjusting screw and spring on the shoes, connecting them together. The coils of the spring must not be over the starwheel on the adjuster. The left and right hand springs are not interchangeable.
  14.  
  15. Spread the shoe assemblies apart and connect the parking brake cable. Install the shoes on the backing plate, engaging the shoes at the top temporarily with the wheel cylinder pistons. Make sure the starwheel on the adjuster is lined up with the adjusting hole in the backing plate, if equipped.
  16.  
  17. Spread the shoes apart slightly and install the parking brake strut and spring. Make sure the end of the strut without the spring engages the parking brake lever. The end with the spring engages the primary shoe (the one with the shorter lining).
  18.  
  19. Install the actuator pivot, lever and return spring. Install the actuating link in the shoe retainer. Lift up the actuator lever and hook the link into the lever.
  20.  
  21. Install the hold-down pins through the back of the plate using J-8057. Install the lever pivots and hold-down springs. Install the shoe return springs using J-8049. Be careful not to stretch or distort the springs.
  22.  
  23. Make sure the linings are in the right place, the self-adjusting mechanism is correctly installed, and the parking brake parts are hooked up.
  24.  
  25. Measure the distance from the edge of the primary lining to the edge secondary lining, then measure the inside width of the drum. Adjust the linings by means of the adjuster so the drum will fit onto the linings.
  26.  
  27. Install the hub and bearing assembly onto the axle if removed. Torque the retaining bolts to 35 ft. lbs. (55 Nm.).
  28.  
  29. Install the drum.
  30.  
  31. Install the wheel and tire assembly.
  32.  
  33. Adjust the brakes. Install a rubber hole cover in the adjustment knock-out hole after the adjustment is complete. Adjust the parking brake.
  34.  
  35. Road test the vehicle and verify proper brake operation.
  36.  


CAUTION
Dust and dirt accumulating on brake parts during normal use may contain asbestos fibers from production or aftermarket brake linings. Breathing excessive concentrations of asbestos fibers can cause serious bodily harm. Exercise care when servicing brake parts. Do not sand or grind brake lining unless equipment used is designed to contain the dust residue. Do not clean brake parts with compressed air or by dry brushing. Cleaning should be done by dampening the brake components with a fine mist of water, then wiping the brake components clean with a dampened cloth. Dispose of cloth and all residue containing asbestos fibers in an impermeable container with the appropriate label. Follow practices prescribed by the Occupational Safety and Health Administration (OSHA) and the Environmental Protection Agency (EPA) for the handling, processing, and disposing of dust or debris that may contain asbestos fibers.

  1. Before servicing the vehicle, refer to the precautions section.
    NOTE
    Brake shoe spanner and spring removal tool J 38400 or its equivalent is required to remove the brake components

  2.  
  3. Remove the wheel assembly.
  4.  
  5. Remove the brake drum. It may be necessary to gently tap the rear edge of the drum to start it off the studs. If extreme resistance to removal is encountered, it will be necessary to retract the brake shoe self-adjuster screw, sometime called the starwheel. Turn the adjuster to retract the linings from the drum.
    NOTE
    Do not hammer on the brake drum to remove it.

  6.  
  7. Remove the adjuster spring.
  8.  
  9. Disengage the adjuster spring hook end from the tab on the adjuster actuator lever, then release the spring from the brake shoe web hole.
  10.  
  11. Remove the adjuster actuator lever from the pivot.
  12.  
  13. Spread the top of the brake shoes apart and remove the adjuster assembly from the brake shoes.
  14.  
  15. Position the hook end of the removal/installation tool under the universal spring and lightly pull the universal spring end out of the shoe web hole.
  16.  
  17. Hold the universal spring with the tool while removing the secondary brake shoe.
  18.  
  19. Release the park brake cable from the park brake lever on the secondary shoe.
  20.  
  21. Position the hook end of the removal/installation tool under the universal spring and lightly pull the universal spring end out of the shoe web hole.
  22.  
  23. Hold the universal spring with the tool while removing the primary brake shoe.
  24.  

To install:

  1. Apply a thin, light coat of high temperature silicone brake lubricant to the brake shoe contact surfaces of the brake backing plate.
  2.  
  3. Position the hook end of the removal/installation tool under the universal spring and lightly pull the universal spring end out while installing the primary brake shoe. ]
  4.  
  5. Ensure that the universal spring engages the brake shoe web hole.
  6.  
  7. Install the park brake cable to the park brake lever on the secondary brake shoe.
  8.  
  9. Position the hook end of the removal/installation tool under the universal spring and lightly pull the universal spring end out while installing the secondary brake shoe.
  10.  
  11. Ensure that the universal spring properly engages the brake shoe web hole.
  12.  
  13. Using the removal/installation tool spread the top of the brake shoes apart and install the adjuster assembly to the brake shoes.
  14.  
  15. Install the adjuster actuator lever to the pivot and the adjuster assembly.
  16.  
  17. Ensure that the lever is properly engaged between the adjuster assembly and the brake shoe.
    NOTE
    Do not over stretch the adjuster spring as damage will occur if the spring is over stretched.

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

  1. Remove the tire and wheel assembly.
  2.  
  3. Remove the brake drum. It may be necessary to gently tap the rear edge of the drum to start it off the studs. If extreme resistance to removal is encountered, it will be necessary to retract the brake shoe self-adjuster screw, sometime called the starwheel. Turn the adjuster to retract the linings from the drum.
    NOTE
    Do not hammer on the brake drum to remove it.

  4.  
  5. Remove the upper return springs from the shoes using tool J-8057 brake spring tool.
  6.  
  7. Remove the hold-down springs using J-8049 brake spring tool.
  8.  
  9. Remove the shoe hold-down pins from behind the brake backing plate.
  10.  
  11. Lift up the actuator lever for the self-adjusting mechanism and remove the actuating link. Remove the actuator lever, pivot, and the pivot return spring.
  12.  
  13. Spread the shoes apart to clear the wheel cylinder pistons, then remove the parking brake strut and spring.
  14.  
  15. Disconnect the parking brake cable from the lever. Remove the shoes, still connected by their adjusting screw spring.
  16.  
  17. With the shoes removed, note the position of the adjusting spring and remove the spring and adjusting screw.
  18.  
  19. Remove the C-clip from the parking brake lever and remove the lever from the secondary shoe.
  20.  
  21. Use a damp cloth to remove all dirt and dust from the backing plate and brake parts.
  22.  

To install:

  1. Check the backing plate attaching bolts to make sure they are tight. Use fine emery cloth to clean all rust and dirt from the shoe contact surfaces on the plate and lubricate with brake grease. Check the wheel cylinder for signs of leakage.

    Click image to see an enlarged view

    Fig. Exploded view of drum brake components-Cavalier, Sunfire

  2.  
  3. Clean all parts completely in brake solvent and air dry.
  4.  
  5. Clean the backing plate shoe contact points.
  6.  
  7. Inspect the inside of the brake drum. If worn, heavily grooved or if the opening is distorted, the drum should be refinished or replaced.
  8.  
  9. Inspect the brake shoe springs and self-adjuster mechanism. Disassemble the adjuster mechanism and clean the threads and coat with grease. Make sure the adjuster assembly turns freely before installing in the vehicle.
  10.  
  11. Install the parking brake lever on the secondary shoe and secure with C-clip.
  12.  
  13. Install the adjusting screw and spring on the shoes, connecting them together. The coils of the spring must not be over the starwheel on the adjuster. The left and right hand springs are not interchangeable.
  14.  
  15. Spread the shoe assemblies apart and connect the parking brake cable. Install the shoes on the backing plate, engaging the shoes at the top temporarily with the wheel cylinder pistons. Make sure the starwheel on the adjuster is lined up with the adjusting hole in the backing plate, if equipped.
  16.  
  17. Spread the shoes apart slightly and install the parking brake strut and spring. Make sure the end of the strut without the spring engages the parking brake lever. The end with the spring engages the primary shoe (the one with the shorter lining).
  18.  
  19. Install the actuator pivot, lever and return spring. Install the actuating link in the shoe retainer. Lift up the actuator lever and hook the link into the lever.
  20.  
  21. Install the hold-down pins through the back of the plate using J-8057. Install the lever pivots and hold-down springs. Install the shoe return springs using J-8049. Be careful not to stretch or distort the springs.
  22.  
  23. Make sure the linings are in the right place, the self-adjusting mechanism is correctly installed, and the parking brake parts are hooked up.
  24.  
  25. Measure the distance from the edge of the primary lining to the edge secondary lining, then measure the inside width of the drum. Adjust the linings by means of the adjuster so the drum will fit onto the linings.
  26.  
  27. Install the hub and bearing assembly onto the axle if removed. Torque the retaining bolts to 35 ft. lbs. (55 Nm.).
  28.  
  29. Install the drum.
  30.  
  31. Install the wheel and tire assembly.
  32.  
  33. Adjust the brakes. Install a rubber hole cover in the adjustment knock-out hole after the adjustment is complete. Adjust the parking brake.
  34.  
  35. Road test the vehicle and verify proper brake operation.
  36.  

 
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