ION, L-Series, S-Series 1999-2005

Brake Shoes

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Adjustment



The Saturn features a self-adjuster mechanism that is part of the brake assembly and compensates for normal brake lining wear. No external adjustment is necessary or possible.

When the brake shoes or components of the brake assembly are replaced, the inside diameter of the drum should be measured using a brake shoe clearance gauge. The outer diameter of the brake shoes should then be given the base setting of 0.020 in. (0.5mm) less than the drum's inner diameter. The automatic adjuster will take care of all adjustments from that point.

The Saturn features a self-adjuster mechanism that is part of the brake assembly and compensates for normal brake lining wear. No external adjustment is necessary or possible.

When the brake shoes or components of the brake assembly are replaced, the inside diameter of the drum should be measured using a brake shoe clearance gauge. The outer diameter of the brake shoes should then be given the base setting of 0.020 in. (0.5mm) less than the drum's inner diameter. The automatic adjuster will take care of all adjustments from that point.

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 the wheels and brake drums.
  2.  
  3. Remove the lower return and adjuster springs using a universal brake spring remover. Do not over extend the springs or they will damaged and will need to be replaced.
  4.  
  5. Compress the leading brake shoe hold-down cup and spring while removing the pin from the rear of the backing plate. Release spring compression, then remove the hold-down cup and spring.
  6.  
  7. Pull the leading shoe towards the front of the vehicle and remove the adjuster assembly and lever. It may be necessary to turn the adjuster starwheel to shorten the adjuster's length.
  8.  
  9. Remove the leading shoe by twisting the shoe out of engagement with the upper return spring.
  10.  
  11. Remove the upper return spring from the park brake shoe, then remove the park brake shoe hold-down cup, spring and pin assembly.
  12.  
  13. Push the park brake shoe lever into the cable spring while disengaging the cable from the end lever and remove the parking brake shoe, lever and cable spring from the vehicle.
  14.  
  15. Remove the retainer and wave washer, then remove the park brake lever from the shoe.
  16.  
  17. Disassemble the brake adjuster socket, screw and nut, then clean the components in denatured alcohol. Inspect the assembly, making sure the screw threads smoothly into the adjusting nut over the full threaded length.
  18.  
  19. Inspect the wheel cylinder for signs of leakage and for cut or damaged boots. Do not attempt to repair a damaged cylinder, the assembly must be replaced.

    Click image to see an enlarged view

    Fig. Rear brake shoe and adjuster installation

  20.  

To install:

  1. Lubricate the adjuster assembly, the 6 backing plate raised shoe contact pads, the brake lever pin and surfaces which contact brake shoe webs with brake lubricant.
  2.  
  3. Install the park brake lever onto the pin on the brake shoe and secure with the wave washer and retainer clip. Crimp the ends of the retainer to secure the brake lever.
  4.  
  5. Install the cable spring into the cage on the park brake lever, then install the cable through the spring and onto the lever.
  6.  
  7. Install the park brake shoe using the hold-down cup assembly; use a universal spring cup remover/installer tool. Make sure the shoe is correctly engaged into the wheel cylinder (top) and the anchor (bottom).
  8.  
  9. Install the long straight end of the upper return spring into the back hole in the park brake shoe, position the other brake shoe and install the other end of the spring into the back of the leading shoe.
  10.  
  11. Pull the lead shoe toward the front of the vehicle and install the adjuster between the park and leading brake shoes. Verify that the adjuster notches properly engage the brake shoe notches and that the shoe is properly aligned in the wheel cylinder and anchor.
  12.  
  13. Install the adjuster lever and adjuster spring. Make sure the notch on the lever engages the pin on the park shoe and the notch on the adjusting socket. The lower leg of the lever should engage the teeth of the starwheel adjuster assembly.
  14.  
  15. Secure the leading brake shoe using the hold-down cup assembly.
  16.  
  17. Install the adjuster spring to the upper side of the brake shoes with the short end to the lead shoe and the long end to the adjuster lever. Then install the lower return spring into the lower holes of the shoes.
  18.  
  19. Verify the correct location of all brake components, if necessary, use the other side brake assembly for comparison.
  20.  
  21. Using a suitable drum clearance gauge, measure the inner diameter of the brake drum and adjust the outside diameter of the brake shoes to 0.02 inch (0.50mm) less than the inner diameter of the drum.
  22.  
  23. Repeat the procedure for the opposite brake shoes and install the brake drums.
  24.  
  25. If the wheel cylinders have been replaced, bleed the hydraulic brake system.
  26.  
  27. Install the rear wheels.
  28.  
  29. Apply and release the brake pedal 20 times to allow the adjuster to properly position the brake shoes.
  30.  
  31. Check and adjust the parking brake cable, as necessary.
  32.  


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 or disconnect the following:

    Wheels and brake drums
     
    Adjuster spring using a universal brake spring remover. Do not over extend the springs or they will damaged and will need to be replaced.
     
    Brake adjuster lever from the pivot
     
    Spread the top of the shoes apart using brake shoe spanner and spring removal tool J 38400
     
    Adjuster assembly
     
    Lightly pull the universal spring end out of the shoe web hole using the hook end of J 38400. Hold the universal spring while removing the trailing shoe.
     
    Park brake cable from the lever
     
    Lightly pull the universal spring end out of the shoe web hole using the hook end of J 38400. Hold the universal spring while removing the leading shoe.
     

  4.  
  5. Inspect the wheel cylinder for signs of leakage and for cut or damaged boots. Do not attempt to repair a damaged cylinder, the assembly must be replaced.
  6.  

To install:

  1. Lubricate the adjuster assembly, the 6 backing plate raised shoe contact pads, the brake lever pin and surfaces which contact brake shoe webs with brake lubricant.
  2.  
  3. Install or connect the following:

    Position the hook end of tool J 38400 under the universal spring and lightly pull the spring end out while installing the leading shoe. Make sure the spring is properly engaged in the shoe web hole.
     
    Park brake cable to the lever
     
    Position the hook end of tool J 38400 under the universal spring and lightly pull the spring end out while installing the trailing shoe. Make sure the spring is properly engaged in the shoe web hole.
     
    Spread the top of the shoes apart using tool J 38400
     
    Adjuster assembly
     
    Adjuster actuator lever to the shoe and adjuster assembly. Make sure the lever is engaged properly between the adjuster and the shoe.
     
    Adjuster spring. Make sure the loop end of the spring engages properly to the tab on the actuator lever
     

  4.  
  5. Release the parking brake.
  6.  
  7. Pull the parking lever boot away from the console after applying light pressure inwards on the boot retainer, this will allow access to the cable adjusting nut.
  8.  
  9. Release the tension on the cable. Make sure to use hand tools only when adjusting the nut.
  10.  
  11. Using a suitable drum clearance gauge, measure the inner diameter of the brake drum and adjust the outside diameter of the brake shoes using the adjuster screw to 0.025 inch (0.50mm) less than the inner diameter of the drum.
  12.  
  13. Repeat the procedure for the opposite brake shoes and install the brake drums.
  14.  
  15. Adjust the parking park and install the lever boot.
  16.  
  17. If the wheel cylinders have been replaced, bleed the hydraulic brake system.
  18.  
  19. Install the rear wheels.
  20.  



Click image to see an enlarged view

Fig. Rear brake shoe and adjuster installation-Saturn

  1. Remove the wheels and brake drums.
  2.  
  3. Remove the lower return and adjuster springs using a universal brake spring remover. Do not over extend the springs or they will damaged and will need to be replaced.
  4.  
  5. Compress the leading brake shoe hold-down cup and spring while removing the pin from the rear of the backing plate. Release spring compression, then remove the hold-down cup and spring.
  6.  
  7. Pull the leading shoe towards the front of the vehicle and remove the adjuster assembly and lever. It may be necessary to turn the adjuster starwheel to shorten the adjuster's length.
  8.  
  9. Remove the leading shoe by twisting the shoe out of engagement with the upper return spring.
  10.  
  11. Remove the upper return spring from the park brake shoe, then remove the park brake shoe hold-down cup, spring and pin assembly.
  12.  
  13. Push the park brake shoe lever into the cable spring while disengaging the cable from the end lever and remove the parking brake shoe, lever and cable spring from the vehicle.
  14.  
  15. Remove the retainer and wave washer, then remove the park brake lever from the shoe.
  16.  
  17. Disassemble the brake adjuster socket, screw and nut, then clean the components in denatured alcohol. Inspect the assembly, making sure the screw threads smoothly into the adjusting nut over the full threaded length.
  18.  
  19. Inspect the wheel cylinder for signs of leakage and for cut or damaged boots. Do not attempt to repair a damaged cylinder, the assembly must be replaced.
  20.  

To install:

  1. Lubricate the adjuster assembly, the 6 backing plate raised shoe contact pads, the brake lever pin and surfaces which contact brake shoe webs with brake lubricant.
  2.  
  3. Install the park brake lever onto the pin on the brake shoe and secure with the wave washer and retainer clip. Crimp the ends of the retainer to secure the brake lever.
  4.  
  5. Install the cable spring into the cage on the park brake lever, then install the cable through the spring and onto the lever.
  6.  
  7. Install the park brake shoe using the hold-down cup assembly; use a universal spring cup remover/installer tool. Make sure the shoe is correctly engaged into the wheel cylinder (top) and the anchor (bottom).
  8.  
  9. Install the long straight end of the upper return spring into the back hole in the park brake shoe, position the other brake shoe and install the other end of the spring into the back of the leading shoe.
  10.  
  11. Pull the lead shoe toward the front of the vehicle and install the adjuster between the park and leading brake shoes. Verify that the adjuster notches properly engage the brake shoe notches and that the shoe is properly aligned in the wheel cylinder and anchor.
  12.  
  13. Install the adjuster lever and adjuster spring. Make sure the notch on the lever engages the pin on the park shoe and the notch on the adjusting socket. The lower leg of the lever should engage the teeth of the starwheel adjuster assembly.
  14.  
  15. Secure the leading brake shoe using the hold-down cup assembly.
  16.  
  17. Install the adjuster spring to the upper side of the brake shoes with the short end to the lead shoe and the long end to the adjuster lever. Then install the lower return spring into the lower holes of the shoes.
  18.  
  19. Verify the correct location of all brake components, if necessary, use the other side brake assembly for comparison.
  20.  
  21. Using a suitable drum clearance gauge, measure the inner diameter of the brake drum and adjust the outside diameter of the brake shoes to 0.02 inch (0.50mm) less than the inner diameter of the drum.
  22.  
  23. Repeat the procedure for the opposite brake shoes and install the brake drums.
  24.  
  25. If the wheel cylinders have been replaced, bleed the hydraulic brake system.
  26.  
  27. Install the rear wheels.
  28.  
  29. Apply and release the brake pedal 20 times to allow the adjuster to properly position the brake shoes.
  30.  
  31. Check and adjust the parking brake cable, as necessary.
  32.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Wheels and brake drums
     
    Adjuster spring using a universal brake spring remover. Do not over extend the springs or they will damaged and will need to be replaced.
     
    Brake adjuster lever from the pivot
     
    Spread the top of the shoes apart using brake shoe spanner and spring removal tool J 38400
     
    Adjuster assembly
     
    Lightly pull the universal spring end out of the shoe web hole using the hook end of J 38400. Hold the universal spring while removing the trailing shoe.
     
    Park brake cable from the lever
     
    Lightly pull the universal spring end out of the shoe web hole using the hook end of J 38400. Hold the universal spring while removing the leading shoe.
     

  4.  
  5. Inspect the wheel cylinder for signs of leakage and for cut or damaged boots. Do not attempt to repair a damaged cylinder, the assembly must be replaced.
  6.  

To install:

  1. Lubricate the adjuster assembly, the 6 backing plate raised shoe contact pads, the brake lever pin and surfaces which contact brake shoe webs with brake lubricant.
  2.  
  3. Install or connect the following:

    Position the hook end of tool J 38400 under the universal spring and lightly pull the spring end out while installing the leading shoe. Make sure the spring is properly engaged in the shoe web hole.
     
    Park brake cable to the lever
     
    Position the hook end of tool J 38400 under the universal spring and lightly pull the spring end out while installing the trailing shoe. Make sure the spring is properly engaged in the shoe web hole.
     
    Spread the top of the shoes apart using tool J 38400
     
    Adjuster assembly
     
    Adjuster actuator lever to the shoe and adjuster assembly. Make sure the lever is engaged properly between the adjuster and the shoe.
     
    Adjuster spring. Make sure the loop end of the spring engages properly to the tab on the actuator lever
     

  4.  
  5. Release the parking brake.
  6.  
  7. Pull the parking lever boot away from the console after applying light pressure inwards on the boot retainer, this will allow access to the cable adjusting nut.
  8.  
  9. Release the tension on the cable. Make sure to use hand tools only when adjusting the nut.
  10.  
  11. Using a suitable drum clearance gauge, measure the inner diameter of the brake drum and adjust the outside diameter of the brake shoes using the adjuster screw to 0.025 inch (0.50mm) less than the inner diameter of the drum.
  12.  
  13. Repeat the procedure for the opposite brake shoes and install the brake drums.
  14.  
  15. Adjust the parking park and install the lever boot.
  16.  
  17. If the wheel cylinders have been replaced, bleed the hydraulic brake system.
  18.  
  19. Install the rear wheels.
  20.  

 
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