Express, Savana, G1500, G2500, G3500, 1998-2005

Brake Shoes

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Adjustment



  1. Raise the vehicle and support it with jack stands.
  2.  
  3. Remove the adjusting hole cover from the rear of the backing plate.
  4.  
  5. Insert a brake adjustment tool into the adjusting hole and turn the starwheel on the adjusting screw while turning the wheel by hand. Keep turning the starwheel until the wheel can just be turned by hand.
  6.  
  7. On vehicles equipped with duo-servo drum brakes, back off the adjusting screw 33 times.
  8.  
  9. On vehicles equipped with leading/trailing drum brakes, back off the adjusting screw 20 times.
  10.  
  11. Perform this procedure at both wheels.
  12.  
  13. Install the adjusting hole cover and check the parking brake adjustment.
  14.  
  15. Lower the vehicle.
  16.  
  17. Make the final adjustment by driving the vehicle very slowly in reverse and pumping the brakes until the self-adjusting mechanisms adjust to the proper level and the brake pedal reaches satisfactory height.
  18.  
  19. Road test the vehicle.
  20.  

  1. Raise the vehicle and support it with jack stands.
  2.  
  3. Remove the adjusting hole cover from the rear of the backing plate.
  4.  
  5. Insert a brake adjustment tool into the adjusting hole and turn the starwheel on the adjusting screw while turning the wheel by hand. Keep turning the starwheel until the wheel can just be turned by hand.
  6.  
  7. On vehicles equipped with duo-servo drum brakes, back off the adjusting screw 33 times.
  8.  
  9. On vehicles equipped with leading/trailing drum brakes, back off the adjusting screw 20 times.
  10.  
  11. Perform this procedure at both wheels.
  12.  
  13. Install the adjusting hole cover and check the parking brake adjustment.
  14.  
  15. Lower the vehicle.
  16.  
  17. Make the final adjustment by driving the vehicle very slowly in reverse and pumping the brakes until the self-adjusting mechanisms adjust to the proper level and the brake pedal reaches satisfactory height.
  18.  
  19. Road test the vehicle.
  20.  

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. Remove or disconnect the following:

    Tire and wheel assembly
     
    Brake drums
     

  2.  
  3. Using denatured alcohol, clean the rear brake shoes.
  4.  
  5. Adjust the brake shoes to the lowest position. This will reduce the tension on the retractor spring.
  6.  
  7. Remove the adjuster spring.
  8.  
  9. Remove the brake adjuster lever.
  10.  
  11. Remove the adjuster assembly.
  12.  
  13. Using a pair of channel locks, remove the retractor spring from the secondary brake shoe.
  14.  
  15. Remove the secondary brake shoe from the backing plate.
  16.  
  17. Using a pair of channel locks, remove the retractor spring from the primary brake shoe.
  18.  
  19. Remove the primary brake shoe from the backing plate.
  20.  
  21. Remove the return spring.
  22.  
  23. Using a small flat-blade screwdriver, press the lock tab for the park brake cable.
  24.  
  25. Hold the lock tab in place.
  26.  
  27. Pushing forward on the park brake cable will unlock the cable from the retainer allowing the cable to be removed from the park brake lever.
  28.  
  29. Push the park brake cable forward.
  30.  
  31. Remove the park brake cable from the lever.
  32.  

To install:

  1. Apply a small amount of high temperature silicone grease or equivalent to the contact areas between the rear brake shoes and the backing plate.
  2.  
  3. Install the park brake cable in the lever. A snap or clip should be felt or heard. This will indicate that the park brake cable is properly in seated in the lever.
  4.  
  5. Install the retractor spring on the backing plate.
  6.  
  7. Using a pair of channel locks, install the retractor spring in the primary brake shoe.
  8.  
  9. Install the secondary brake shoe on the backing plate.
  10.  
  11. Using channel locks, install the retractor spring in the secondary brake shoe.
  12.  
  13. Install the adjuster spring.
  14.  
  15. Install the brake adjuster lever.
  16.  
  17. Install the adjuster assembly.
  18.  
  19. Adjust the rear brake shoes.
  20.  
  21. Install the rear brake drum.
  22.  

  1. Remove or disconnect the following:

    Tire and wheel assembly
     
    Brake drums
     

  2.  
  3. Using denatured alcohol, clean the rear brake shoes.
  4.  
  5. Adjust the brake shoes to the lowest position. This will reduce the tension on the retractor spring.
  6.  
  7. Remove the adjuster spring.
  8.  
  9. Remove the brake adjuster lever.
  10.  
  11. Remove the adjuster assembly.
  12.  
  13. Using a pair of channel locks, remove the retractor spring from the secondary brake shoe.
  14.  
  15. Remove the secondary brake shoe from the backing plate.
  16.  
  17. Using a pair of channel locks, remove the retractor spring from the primary brake shoe.
  18.  
  19. Remove the primary brake shoe from the backing plate.
  20.  
  21. Remove the return spring.
  22.  
  23. Using a small flat-blade screwdriver, press the lock tab for the park brake cable.
  24.  
  25. Hold the lock tab in place.
  26.  
  27. Pushing forward on the park brake cable will unlock the cable from the retainer allowing the cable to be removed from the park brake lever.
  28.  
  29. Push the park brake cable forward.
  30.  
  31. Remove the park brake cable from the lever.

    Click image to see an enlarged view

    Fig. Exploded view of the brake shoes

  32.  

To install:

  1. Apply a small amount of high temperature silicone grease or equivalent to the contact areas between the rear brake shoes and the backing plate.
  2.  
  3. Install the park brake cable in the lever. A snap or clip should be felt or heard. This will indicate that the park brake cable is properly in seated in the lever.
  4.  
  5. Install the retractor spring on the backing plate.
  6.  
  7. Using a pair of channel locks, install the retractor spring in the primary brake shoe.
  8.  
  9. Install the secondary brake shoe on the backing plate.
  10.  
  11. Using channel locks, install the retractor spring in the secondary brake shoe.
  12.  
  13. Install the adjuster spring.
  14.  
  15. Install the brake adjuster lever.
  16.  
  17. Install the adjuster assembly.
  18.  
  19. Adjust the rear brake shoes.
  20.  
  21. Install the rear brake drum.
  22.  

Duo-Servo Brakes

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. Raise the vehicle and support it safely.
  2.  
  3. Remove the tire and wheel assembly.
  4.  
  5. Remove the brake drums.
  6.  
  7. Using a brake tool, remove the shoe return springs.
  8.  
  9. Remove the shoe guide.
  10.  
  11. Remove the hold-down springs and pins.
  12.  
  13. Remove the actuator lever and pivot.
  14.  
  15. Remove the lever return spring.
  16.  
  17. Remove the actuator link, parking brake strut, spring retaining ring.
  18.  
  19. Remove the parking brake lever and washer.
  20.  
  21. Remove the shoe assemblies.
  22.  
  23. Remove the adjuster screw and spring from the shoe assembly.

    Click image to see an enlarged view

    Fig. Exploded view of the rear drum brake assembly-G-Series Van, Savana with Duo-Servo type

  24.  

To install:

  1. Use a brake cleaning fluid to remove dirt from the brake drum. Check the drums for scoring, cracks and for out-of-round; service the drums as necessary.
  2.  
  3. Check the wheel cylinders by carefully pulling the lower edges of the wheel cylinder boots away from the cylinders. If there is excessive leakage, the inside of the cylinder will drip fluid; repair or replace as necessary.
  4.  
  5. Check the flange plate, which is located around the axle, for leakage of differential lubricant.
  6.  
  7. Lightly lubricate the parking brake cable, parking brake lever where it enters the shoe and the backing plate-to-shoe contact points. Use high temperature, waterproof, grease or special brake lube.
  8.  
  9. Install the parking brake lever into the secondary shoe with the attaching bolt, spring washer, lockwasher, and nut. It is important that the lever move freely before the shoe is attached. Move the assembly and check for proper action.
  10.  
  11. Lubricate the adjusting screw and make sure it works freely.
  12.  
  13. Connect the adjuster screw and spring to the bottom portion of both shoes. Ensure the spring does not interfere with the adjuster rotation when installed. The primary (smaller shoe pad area) to the front and secondary shoe (larger shoe pad area) to the rear of the vehicle.
  14.  
  15. Install the shoe assembly. Ensuring the shoe webs are positioned correctly against the wheel cylinder.
  16.  
  17. Install the parking brake cable.
  18.  
  19. Secure the primary shoes with the hold-down pin and spring.
  20.  
  21. Install the parking brake strut and the strut spring.
  22.  
  23. Install the actuator lever and pivot, securing the assembly with the hold-down pin and spring. Install the actuator link and spring.
  24.  
  25. Install the return springs.
  26.  
  27. Check the operation of the self-adjusting mechanism by moving the actuating lever by hand.
  28.  
  29. Adjust the brakes and install the drum.
  30.  
  31. Adjust the parking brake.
  32.  
  33. Install the tire and wheel assembly.
  34.  
  35. Lower the vehicle.
  36.  

Leading/Trailing Brakes

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. Raise the vehicle and support it safely.
  2.  
  3. Remove the tire and wheel assembly.
  4.  
  5. Remove the brake drums.
  6.  
  7. Raise the lever arm of the actuator until the upper end is clear of the slot in the adjuster screw.
  8.  
  9. Slide the actuator off the adjuster pin. Disconnect the actuator spring from the shoe.
  10.  
  11. Remove the hold-down spring assemblies and pins.
  12.  
  13. Pull the bottom ends of the shoes apart and lift the lower return spring over the anchor plate. Allow the shoe ends to come together and remove the spring.
  14.  
  15. Remove the shoe assembly, along with the upper return spring and the adjusting screw assembly.
  16.  
  17. Remove the upper return spring and the adjusting screw assembly from the shoes.
  18.  
  19. Remove the retaining ring, pin, spring washer, and parking brake lever.

    Click image to see an enlarged view

    Fig. Exploded view of the rear drum brake assembly-G-Series Van, Savana with Leading/Trailing type

  20.  

To install:

  1. Clean adjuster wheel and the backing plates with a suitable cleaner. Lubricate the backing plate contact points, levers and adjuster with a suitable lubricant.
  2.  
  3. Assemble the parking lever, spring washer (concave side facing the brake lever), pin, and retaining ring onto the rearward shoe.
  4.  
  5. Install the adjuster pin in the forward shoe with the pin projecting 0.276 in. (7mm) from the side of the shoe web where the adjuster actuator is installed.
  6.  
  7. With the brake shoes resting on a flat surface (the shoe with the parking lever to the rear of the vehicle), install the upper return spring.
  8.  
  9. Install the adjuster screw assembly with the spring clip facing the backing plate.
  10.  
  11. Place the shoes in position on the backing plate. Do not place the lower shoe webs under the anchor plate.
  12.  
  13. Install the lower return spring, spread the bottom of the shoes and position the shoe against the backing plate.
  14.  
  15. Install the hold-down pins and spring assemblies.
  16.  
  17. Install the adjuster actuator over the end of the adjuster pin so the top leg engages the notch in the adjuster screw.
  18.  
  19. Install the actuator spring, being careful not to over-stretch it more than 3.27 in. (83mm).
  20.  
  21. Install the parking brake cable to the lever.
  22.  
  23. Adjust the parking brake if the shoes will not totally retract.
  24.  
  25. Install the drum, tire and wheel assembly. Adjust the rear brakes and lower the vehicle.
  26.  

 
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