Chrysler Full-Size Vans 1989-1998 Repair Guide

Brake Drums

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REMOVAL & INSTALLATION




CAUTION
Older brake pads or shoes may contain asbestos, which has been determined to be 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.

See Figures 1, 2 and 3



Click image to see an enlarged view

Fig. Fig. 1: Insert a screwdriver and adjusting tool through the access hole in the brake backing plate



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Fig. Fig. 2: Disengage the lever to relieve pressure from the star wheel



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Fig. Fig. 3: Remove the drum by pulling it off the axle flange. It might be necessary to lightly tap with a hammer to remove built-up rust

11 Inch Brakes

These brakes are used with a conventional axle assembly in 150 and 250 series vans.

  1. Raise and safely support the vehicle securely on jackstands.
  2.  
  3. Remove the plug from the brake adjustment access hole.
  4.  
  5. Insert a thin bladed tool or a piece of stiff wire through the adjusting hole and hold the adjusting lever away from the star wheel.
  6.  
  7. Release the brake shoes by prying down against the star wheel with a brake adjusting tool.
  8.  
  9. Remove the rear wheel and clips from the wheel studs.
  10.  

The brake drum may be filled with brake dust. Take all appropriate cautions to avoid inhaling the dust.

  1. Remove the brake drum.
  2.  

To install:
  1. Position the brake drum on the hub.
  2.  
  3. Install the retaining clips on the studs.
  4.  
  5. Install the rear wheels.
  6.  
  7. Adjust the brake shoes prying up against the star wheel with a brake adjusting tool. The brakes should be adjusted so there is a slight drag on the wheel when rotated.
  8.  
  9. Lower the vehicle.
  10.  

12 Inch Brakes

These brakes are used with a full floating axle assembly in 350 series vans.

  1. Raise and safely support the vehicle securely on jackstands.
  2.  
  3. Remove the plug from the brake adjustment access hole.
  4.  
  5. Insert a thin bladed tool or a piece of stiff wire through the adjusting hole and hold the adjusting lever away from the star wheel.
  6.  
  7. Release the brake shoes by prying down against the star wheel with a brake adjusting tool.
  8.  
  9. Remove the axle shaft nuts, washers and cones. If the cones do not readily release, tap the axle shaft sharply in the center with a brass hammer.
  10.  
  11. Remove the axle shaft.
  12.  
  13. Remove the outer hub nut.
  14.  
  15. Straighten the lockwasher tab and remove it, along with the inner nut and bearing.
  16.  

The brake drum may be filled with brake dust. Take all appropriate precautions to avoid inhaling the dust.

  1. Carefully remove the drum.
  2.  

To install:
  1. Position the drum on the axle housing.
  2.  
  3. Install the bearing and inner nut. While rotating the wheel and tire, tighten the adjusting nut until a slight drag is felt.
  4.  
  5. Back off the adjusting nut 1 / 6 turn so that the wheel rotates freely without excessive end-play.
  6.  
  7. Install the lockrings and nut. Place a new gasket on the hub and install the axle shaft, cones, lockwashers and nuts.
  8.  
  9. Install the rear wheels.
  10.  
  11. Adjust the brake shoes prying up against the star wheel with a brake adjusting tool. The brakes should be adjusted so that there is a slight drag on the wheel when rotated.
  12.  
  13. Lower the vehicle.
  14.  

INSPECTION



See Figure 4

Check that there are no cracks or chips in the braking surface. Excessive bluing indicates overheating and a replacement drum is needed. The drum can be machined to remove minor damage and to establish a perfectly round braking surface on a warped drum. Never exceed the maximum oversize of the drum when machining the braking surface. The maximum inside diameter is stamped on the rim of the drum.



Click image to see an enlarged view

Fig. Fig. 4: The maximum diameter stamping on the drum usually looks like this; you may have to clean it to read it clearly

 
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