1991 1999 ford explorer chilton User Manual

							... and disconnect the pivot hook from the adjusting lever. Wind the starwheel all the way in
Pull the adjusting lever, cable and automatic adjuster spring down and toward the rear to unhook the
pivot hook from the large hole in the secondary shoe web. Do not attempt to pry the pivot hook from
the hole.
4. 
Remove the automatic adjuster spring and the adjusting lever.
5. 
Remove the primary shoe-to-anchor spring with a brake tool. (Brake tools are very common and are
available at auto parts stores). Remove the secondary shoe-to-anchor spring and unhook the cable
anchor. Remove the anchor pin plate.
6. 
Disconnect the adjuster lever return spring from the lever ...HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 1021 
						

							... and remove the spring and the lever
Next, using a brake spring removal tool ...
... disconnect the primary brake shoe return spring from the anchor pin HOW TO USE THIS BOOK
1022 REMOVAL & INSTALLATION 
						

							Repeat the procedure and remove the secondary return spring, adjuster cable and its guide
Also remove the anchor pin plate
Remove the cable guide from the secondary shoe.
7. 
Remove the shoe hold-down springs, shoes, adjusting screw, pivot nut, and socket. Note the color of
each hold-down spring for assembly. To remove the hold-down springs, reach behind the brake
backing plate and place one finger on the end of one of the brake hold-down spring mounting pins.
Using a pair of pliers, grasp the washer-type retainer on top of the hold-down spring that corresponds
to the pin that you are holding. Push down on the pliers and turn them 90° to align the slot in the
washer with the head on the spring mounting pin. Remove the spring and washer retainer and repeat
this operation on the hold-down spring on the other shoe.
8. 
Remove the parking brake link and spring. Disconnect the parking brake cable from the parking brake
lever.
9. 
After removing the rear brake secondary shoe, disassemble the parking brake lever from the shoe by
removing the retaining clip and spring washer.
10.  HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 1023 
						

							Pull the bottoms of the shoes apart and remove the adjuster screw assembly
Press in the hold-down springs while holding in on the nail from behind, then turn the cup 90ß ...
... and release to remove the hold-down spring. Pull the nail out from the backing plate HOW TO USE THIS BOOK
1024 REMOVAL & INSTALLATION 
						

							Remove the primary (front) brake shoe from the backing plate ...
... and the parking brake strut as well
Remove the secondary shoe hold-down, pull the shoe out then press up on the cable spring ... HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 1025 
						

							... and disconnect the parking brake cable from its lever by pulling it from the slot
To assemble and install the brake shoes:
Lightly apply the proper grade of lubricant to the points shown on the backing plate Click to enlarge
Assemble the parking brake lever to the secondary shoe and secure it with the spring washer and
retaining clip.
11.  HOW TO USE THIS BOOK
1026 REMOVAL & INSTALLATION 
						

							Apply a light coating of Lubriplate® at the points where the brake shoes contact the backing plate.
12. 
Position the brake shoes on the backing plate, and install the hold-down spring pins, springs, and
spring washer-type retainers. Install the parking brake link, spring and washer. Connect the parking
brake cable to the parking brake lever.
13. 
Install the anchor pin plate, and place the cable anchor over the anchor pin with the crimped side
toward the backing plate.
14. 
Install the primary shoe-to-anchor spring with the brake tool.
15. 
Install the cable guide on the secondary shoe web with the flanged holes fitted into the hole in the
secondary shoe web. Thread the cable around the cable guide groove.
16. 
Install the secondary shoe-to-anchor (long) spring. Be sure that the cable end is not cocked or
binding on the anchor pin when installed. All of the parts should be flat on the anchor pin. Remove
the wheel cylinder piston clamp.
17. 
Apply Lubriplate® to the threads and the socket end of the adjusting starwheel screw. Turn the
adjusting screw into the adjusting pivot nut to the limit of the threads and then back off  1
/2  turn.
18. 
Interchanging the brake shoe adjusting screw assemblies from one side of the vehicle to the other would
cause the brake shoes to retract rather than expand each time the automatic adjusting mechanism
operated. To prevent this, the socket end of the adjusting screw is stamped with an R or an L for
RIGHT or LEFT. The adjusting pivot nuts can be distinguished by the number of lines machined
around the body of the nut; one line indicates left hand nut and 2 lines indicates a right hand nut.
Place the adjusting socket on the screw and install this assembly between the shoe ends with the
adjusting screw nearest to the secondary shoe.
19. 
Place the cable hook into the hole in the adjusting lever from the backing plate side. The adjusting
levers are stamped with an R(right) or an L(left) to indicate their installation on the right or left hand
brake assembly.
20. 
Position the hooked end of the adjuster spring in the primary shoe web and connect the loop end of
the spring to the adjuster lever hole.
21. 
Pull the adjuster lever, cable and automatic adjuster spring down toward the rear to engage the pivot
hook in the large hole in the secondary shoe web.
22. 
After installation, check the action of the adjuster by pulling the section of the cable between the cable
guide and the adjusting lever toward the secondary shoe web far enough to lift the lever past a tooth
on the adjusting screw starwheel. The lever should snap into position behind the next tooth, and
release of the cable should cause the adjuster spring to return the lever to its original position. This
return action of the lever will turn the adjusting screw starwheel one tooth. The lever should contact
the adjusting screw starwheel one tooth above the center line of the adjusting screw.
23.  HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 1027 
						

							Exploded view of a typical brake adjuster assembly
Click to enlarge
The return spring and adjuster correctly installed HOW TO USE THIS BOOK
1028 REMOVAL & INSTALLATION 
						

							Correct adjuster cable routing, drivers side shown
Click to enlarge
View of the rear drum brake shoes completely assembled to the backing plate
If the automatic adjusting mechanism does not perform properly, check the following:
Check the cable end fittings. The cable ends should fill or extend slightly beyond the crimped section
of the fittings. If this is not the case, replace the cable.
24. 
Check the cable guide for damage. The cable groove should be parallel to the shoe web, and the body
of the guide should lie flat against the web. Replace the cable guide if this is not so.
25. 
Check the pivot hook on the lever. The hook surfaces should be square with the body on the lever for
proper pivoting. Repair or replace the hook as necessary.
26. 
Make sure that the adjusting screw starwheel is properly seated in the notch in the shoe web.
27. 
ADJUSTMENTS HOW TO USE THIS BOOK
ADJUSTMENTS 1029 
						

							Brake shoe adjustment gauge- Step 1
Brake shoe adjustment gauge- Step 2 HOW TO USE THIS BOOK
1030 ADJUSTMENTS