DIY Brake Job

Disc Brake Repair

• 1

  Park the vehicle on a level surface. Set the parking brake if working on front brakes. Block the front wheels if working on rear brakes. Put automatic transmissions in park, and manual transmissions in first or reverse gear. Partially loosen the lug nuts. Jack up the vehicle and set it securely on safety stands.

• 2

  Remove the two caliper guide bolts. Rock the caliper back and forth to force the brake pads apart slightly. Lift the caliper assembly up and off the disc. Do not damage the flexible brake hose. Support the caliper in a secure location using a wire hook or a bungee cord.

• 3

  Pry off the brake-pad retaining clips. Do not damage the clips. Remove the brake pads and shims from the caliper.

• 4

  Push the caliper piston back into the cylinder with a piston retractor. Place the retractor metal plate against the inner surface of the outside caliper frame and place the spindle swivel against the piston. Tighten the spindle to push the piston into the cylinder. Be careful not to damage the rubber piston seal.

• 5

  Remove the two disc-retaining screws. Remove the disc by pulling it straight off the hub. If the disc is seized, tap the inner part of the disc firmly with a hammer to loosen. Do not hit the disc braking surface or outer rim.

• 6

  Check the brake pad lining thickness. The minimum thickness specified in the shop manual is 0.0787-inch. If the lining thickness is below the allowable minimum, or if the linings show uneven wear or damage, replace the pads.

• 7

  Check the disc outer rim. The new disc thickness and the minimum allowable thickness are stamped into the metal. Measure the disc thickness at several locations using a brake-disc micrometer. If less than the allowable minimum, or if the disc is warped or cracked, replace it. The disc can be machined at a brake shop or auto parts store to repair minor damage.

• 8

  Coat the caliper guide bolts liberally with brake grease. Follow steps in reverse order to reassemble the brake. Start the vehicle and check the brake function. Replace the wheel. Lower the vehicle.

Drum Brake Repair

• 9

  Park the vehicle on a level surface. Put automatic transmissions in park and manual transmissions in first or reverse gear. Securely block the front wheels. Leave the parking brake off. Partially loosen the lug nuts on both rear wheels. Jack up the rear of the vehicle and set it securely on safety stands. Remove both rear wheels.

• 10

  Remove the two drum retaining bolts. Pull the drum off the hub. If the drum is seized, thread 8-mm bolts into the two threaded holes on the drum face and tighten evenly to jack the drum off of the hub.

• 11

  Grip the end of the top return spring with pliers and unhook it from the front brake shoe. Unhook the other end of the spring from the rear brake shoe and remove the spring.

• 12

  Remove the front-brake-shoe spring clip with pliers, and then push the hold-down pin out through the backing plate. Repeat for the rear-brake-shoe.

• 13

  Remove the anti-rattle spring and adjuster spring by unhooking the spring ends from their fastening points with pliers.

• 14

  Carefully note the operating lever position. Take a photo if possible so that the lever can be replaced in the same position during reassembly. Remove bottom return spring by unhooking the ends from the brake shoes.

• 15

  Remove the clip and washer from the end of the parking brake cable and remove the cable from the rear brake shoe. Remove the front and rear brake shoes.

• 16

  Measure the inside drum diameter with a brake drum micrometer. The diameter must be equal in all directions. The Shop Manual specifies a maximum diameter of 7.87-inches. Replace the drum if the interior surface shows deep grooves, pitting, or cracks, or if the inside diameter exceeds the specified maximum. Have the drum machined at a brake shop or auto parts store to repair minor damage.

• 17

  Check the shoe lining thickness. The minimum allowable thickness specified in the shop manual is 0.04-inch. If the lining thickness is below the allowable minimum, then the shoes must be replaced.

• 18

  Clean all parts with brake cleaning fluid. Remove stubborn dirt with rags or a wire brush. Capture used fluid in a catch pan and dispose of properly. Apply brake grease to the two points where each shoe touches the backing plate, the points where the brake cylinder contacts each brake shoe, and the pivot points for the operating lever and the brake shoe hold-down pins.

• 19

  Follow steps in reverse order to reassemble the brake. Position the operating lever as it was before disassembly. Use the assembled brake on the opposite side as a guide. Start the vehicle and pump the brakes to set the mechanism. Repeat the procedure on the brake on the other side. Replace the wheels. Lower the vehicle.