Malibu 2001-2005

Brake Shoes

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Adjustment




WARNING
Some models or aftermarket brake parts may contain asbestos fibers which can become airborne in dust. Breathing dust with asbestos fibers may cause serious bodily harm. Use a water-dampened cloth in order to remove any dust on brake parts. Equipment is available commercially in order to perform this washing function. These wet methods prevent fibers from becoming airborne.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Raise and support the vehicle.
  4.  
  5. Remove the rear tire and wheel assemblies.
  6.  
  7. Ensure that the park brake lever is in the fully released position.
  8.  
  9. Pull down on the front cable and disconnect the short cable leading to the drum backing plate from the cable connector. Do this step for both sides of the vehicle in order to ensure no cable drag is present.

    Click image to see an enlarged view

    Fig. Parking brake cables and connector

  10.  
  11. Remove the rear brake drums.
  12.  
  13. Position the J 21177-A clearance gage to widest point of the brake drum inside diameter.
  14.  
  15. Firmly hand tighten the set screw on the J 21177-A.

    Click image to see an enlarged view

    Fig. Positioning the J 21177-A to the widest point of the brake drum inside diameter

  16.  
  17. Remove the J 21177-A from the brake drum and position it over the corresponding brake shoe assembly at its widest point.
  18.  
  19. While holding the J 21177-A in position, insert a 0.025 inch. (0.635 mm) feeler gage between one side of the J 21177-A, and the corresponding brake shoe.
  20.  
  21. Rotate the brake shoe adjuster screw until the brake shoes contact the J 21177-A, and the feeler gage.
    NOTE
    Brake shoe-to-drum clearance: 0.025 inch. (0.635 mm)



    Click image to see an enlarged view

    Fig. Rotate the brake shoe adjuster screw until the brake shoes contact the J 21177-A

  22.  
  23. Repeat the above steps for the opposite brake drum and brake shoe assembly.
  24.  
  25. Install the brake drums.
  26.  
  27. Pull down on the front cable and connect the short cable leading to the drum backing plate to the cable connector. Repeat for opposite side.
  28.  
  29. Adjust the park brake.
  30.  
  31. Install the rear tire and wheel assemblies.
  32.  
  33. Lower the vehicle.
  34.  

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.
  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 and 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 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. Drum brake components, exploded view-Malibu

  2.  
  3. Clean all parts completely in brake solvent and air dry. Clean the backing plate shoe contact points.
  4.  
  5. Inspect the inside of the brake drum. If worn, heavily grooved or if the opening is distorted, the drum should be refinished or replaced.
  6.  
  7. 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.
  8.  
  9. Install the parking brake lever on the secondary shoe and secure with C-clip.
  10.  
  11. Install the adjusting screw and spring on the shoes, connecting them together. The coils of the spring must not be over the star wheel on the adjuster. The left and right hand springs are not interchangeable.
  12.  
  13. Spread the shoe assemblies 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 star wheel on the adjuster is lined up with the adjusting hole in the backing plate, if equipped.
  14.  
  15. Spread the shoes 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).
  16.  
  17. 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.
  18.  
  19. 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.
  20.  
  21. Make sure the linings are in the right place, the self-adjusting mechanism is correctly installed, and the parking brake parts are hooked up.
  22.  
  23. 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.
  24.  
  25. Install the hub and bearing assembly onto the axle if removed. Torque the retaining bolts to 35 ft. lbs. (55 Nm).
  26.  
  27. Install the drum and the wheels.
  28.  
  29. Adjust the brakes. Install a rubber hole cover in the adjustment knock-out hole after the adjustment is complete. Adjust the parking brake.
  30.  
  31. Road test the vehicle and verify proper brake operation.
  32.  


WARNING
Some models or aftermarket brake parts may contain asbestos fibers which can become airborne in dust. Breathing dust with asbestos fibers may cause serious bodily harm. Use a water-dampened cloth in order to remove any dust on brake parts. Equipment is available commercially in order to perform this washing function. These wet methods prevent fibers from becoming airborne.

  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.
  8.  
  9. Remove the adjuster spring.

    Click image to see an enlarged view

    Fig. Adjuster spring removal

  10.  
  11. Remove the adjuster actuator lever from the pivot.
  12.  
  13. Use the J 38400 to spread the top of the brake shoes to remove the adjuster assembly from the brake shoes.

    Click image to see an enlarged view

    Fig. J 38400 used to spread the top of the brake shoes

  14.  
  15. Position the hook end of the J 38400 under the universal spring and lightly pull the universal spring end out of the shoe web hole. Hold the universal spring with the tool while removing the brake shoe.

    Click image to see an enlarged view

    Fig. J 38400 used to release universal spring

  16.  
  17. Release the park brake cable from the park brake lever.
  18.  
  19. Position the hook end of the J 38400 under the universal spring and lightly pull the universal spring end out of the shoe web hole. Hold the universal spring with the tool while removing the brake shoe.
  20.  

To install:

  1. Apply a thin, light coat of high temperature silicone brake lubricant to the contact surfaces of the right and left brake backing plates.
  2.  
  3. Position the hook end of the J 38400 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.
  4.  
  5. Position the hook end of the J 38400 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.
  6.  
  7. Install the park brake cable to the park brake lever on the brake shoe.
  8.  
  9. Use the J 38400 to spread the top of the brake shoes to install the adjuster assembly.
  10.  
  11. Install the adjuster actuator lever to the pivot.
  12.  
  13. Install the adjuster spring.
  14.  
  15. Adjust the drum brake system.
  16.  
  17. Install the brake drum.
  18.  
  19. Install the tire and wheel assembly.
  20.  
  21. Lower the vehicle.
  22.  

 
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