DRUM BRAKES

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Introduction

CAUTION

Older brake pads or shoes may contain asbestos, which has been determined to be cancer causing agent. Never clean the brake surface with compressed air! Avoid inhaling any dust from any brake surface! When cleaning brake surfaces, use a commercially available brake cleaning fluid.

Cirrus, Stratus and Breeze models are equipped with a 2 shoe (leading/trailing), internal expanding type of rear drum brakes with automatic self-adjuster mechanisms. The automatic self-adjuster mechanisms used on these vehicles are new designs and function differently than the screw type adjusters used in the past. These new self-adjusters are still actuated each time the vehicle's service brakes are applied. The new adjusters are located directly below the wheel cylinders.

The Sebring coupe, convertible and Avenger models are equipped with a rear wheel, 2 shoe (leading/trailing) internally expanding type of drum brakes with an automatic self-adjuster mechanism. The automatic self-adjuster mechanism used on these vehicles is the screw type adjuster. The self-adjuster mechanism is actuated each time the vehicle's service brakes are applied. Generally, drum brakes with a self-adjusting mechanism do not require manual brake shoe adjustment. Although, in the event that the brake shoes are replaced, it is advisable to make the initial adjustment manually to speed up the initial adjustment time. The initial adjustment procedure must be done prior to driving the vehicle.

Drum Brake Components

Click to enlargeBrake Drums

REMOVAL & INSTALLATION

1. Raise and safely support the vehicle.

2. Remove the rear tire and wheel assembly.

If the vehicle has high mileage, the brake drums may have a ridge worn in them by the brake shoes. This ridge causes the brake drum to interfere with the brake shoes, thereby preventing drum removal. Clearance can be obtained by backing off the brake's automatic self-adjuster mechanism, using the following procedures.

Backing off the rear brake shoe adjustment

Click to enlarge3. For Cirrus, Stratus and Breeze models, use the following procedure:

1. Locate and remove the rubber plug from the brake support plate (backing plate).

2. Insert a brake adjuster tool or similarly-shaped prytool through the automatic adjuster access hole and engage the teeth on the adjuster wheel. Rotate the adjuster wheel so it is moved toward the front of the vehicle. Continue moving the adjuster until it stops; this will back off the adjustment of the rear brake shoes.

4. For Sebring coupe, convertible and Avenger models, use the following procedure for releasing the self-adjusting mechanism:

1. Locate and remove the rubber plug from the brake support plate (backing plate).

2. Insert a brake adjuster tool or similarly shaped prytool through the automatic adjuster access hole and carefully push the adjuster actuating lever out of engagement with the adjuster star wheel. While holding the lever away from the star wheel, insert a second prytool through the access hole and engage the teeth on the adjuster wheel. Rotate the adjuster wheel upward away from the ground; this will back off the adjustment of the rear brake shoes.

After removing the rear wheel, pull off the brake drum

5. Remove the brake drum from the hub assembly.

To install:

6. Inspect the brake drum for cracks or signs of overheating. Measure the drum run-out and diameter. If not to specification, resurface the drum. Run-out should not exceed 0.006 in. (0.15mm). The diameter variation (oval shape) of the drum braking surface must not exceed either 0.0025 in. (0.064mm) in 30 degrees of rotation, or 0.0035 in. (0.089mm) in 360 degrees of rotation. All brake drums are marked with the maximum allowable brake drum diameter on the face of the drum.

7. Install the brake drum onto the hub assembly.

8. Install the tire and wheel assembly. Tighten the lug nuts in a star pattern to 95 ft. lbs. (129 Nm).

9. If necessary, repeat Steps 2-8 for the other brake drum.

10. Properly adjust the rear brakes.

11. Lower the vehicle.

12. Road test the vehicle to check for proper brake operation.

INSPECTION

1. Inspect the brake drums for cracks, signs of overheating or excessive wear.

2. On Cirrus, Stratus, Sebring convertible and Breeze models, perform the following inspection checks:

1. Measure the drum run-out and diameter. If not to specification, resurface the drum. Run-out should not exceed 0.006 inch (0.15mm). The diameter variation (oval shape) of the drum braking surface must not exceed either 0.0025 inch (0.064mm) in 30 rotation, or 0.0035 inch (0.089mm) in 360 rotation.

Inspecting the brake drum inside diameter

The maximum machining diameter is cast into the outer rim of the brake drum

3. On the Sebring coupe and Avenger models, measure the brake drum's inside diameter. Wear limit on the brake drum inside diameter is 230.6mm (9.0 inches).

All brake drums are marked with the maximum allowable brake drum diameter on the face of the drum.

Brake Shoes

INSPECTION

1. On Cirrus, Stratus, Sebring convertible and Breeze models, measure the combined thickness of the brake shoe rim and lining. The minimum leading brake shoe rim and lining thickness specification is 1/8 inch (3.0mm). The minimum trailing brake shoe rim and lining thickness specification is 7/64 inch (2.8mm).

Brake shoe lining thickness measurement-Cirrus, Stratus, Sebring convertible and Breeze

Brake shoe lining thickness measurement-Sebring coupe and Avenger

2. On Sebring coupe and Avenger models, measure the thickness of the brake shoe lining material only. The minimum brake shoe lining thickness specification is 3/64 (1.0mm).

3. If any of the measurements fall below the minimum specifications, replace the brake shoes.

4. Thoroughly clean all parts. The brake lining should show contact across the entire width and from heel to toe; otherwise, replace. Clean and inspect the brake support plate and the automatic adjuster mechanism. Be sure that the adjuster mechanism has full movement throughout it adjustment range and that its teeth should be in good condition. If the adjuster is worn or damaged, replace it. If the adjuster is serviceable, lubricate the moving parts with high-temperature grease. Check the brake springs. Overheating indications are paint discoloration or distorted end coils. Replace parts as required.

REMOVAL & INSTALLATION

Cirrus, Stratus and Breeze

Remove the actuating spring from the adjuster mechanism and trailing brake shoe

Remove the upper spring using needlenose pliers

Notice that the hooks on each end of the spring are different, so it can only be installed one way

Remove the lower return spring from the brake shoes

Unfasten the trailing brake shoe retainer support plate

Remove the retainer and pin attaching the trailing brake shoe assembly to the brake support plate

Remove the leading brake shoe and adjuster mechanism as an assembly

Remove the adjuster mechanism from the brake shoe

Use pliers to separate the parking brake cable from the actuating lever

Unlike most actuating levers, this actuator is permanently attached to the shoe by a rivet

Clean the brake shoe contact points of the backing plate ...

... then lubricate the contact points

1. Raise and safely support the vehicle.

2. Remove the rear tire and wheel assemblies.

Regardless of their wear pattern, when brake shoes are replaced on one side of the vehicle, they must also be replaced on the other side. It is advisable, however, to complete one side before beginning the other.

3. Remove the brake drum from the hub assembly.

4. Remove the actuating spring from the adjuster mechanism and trailing brake shoe.

5. Remove the upper return spring from the brake shoes.

6. Remove the lower return spring from the brake shoes.

7. Remove the brake shoe retainer and pin attaching the leading brake shoe assembly to the brake support plate.

8. Remove the leading brake shoe and adjuster mechanism as an assembly from the rear brake support plate. The adjuster mechanism cannot be separated from the leading brake shoe until the brake shoe and adjuster mechanism is removed from the support plate.

9. Remove the trailing brake shoe retainer and pin attaching the trailing brake shoe assembly to the brake support plate. Remove the trailing brake shoe assembly.

On this vehicle, the parking brake actuating lever is permanently attached to the trailing brake shoe assembly. Do not attempt to remove it from the original brake shoe assembly or reuse the original actuating lever on a replacement brake shoe assembly. All replacement brake shoe assemblies for this vehicle must have the actuating lever as part of the trailing brake shoe assembly.

10. Remove the parking brake cable from the parking brake lever. Do not remove the lever from the brake shoe.

11. Remove the automatic adjuster mechanism from the brake shoe by fully extending the adjuster, then rotating the adjuster to release from the brake shoe.

To install:

12. Lubricate the 8 brake shoe contact points with high-temperature grease.

The trailing brake shoe assemblies used on the rear brakes of this vehicle are unique (handed) for the left and right side of the vehicle. Care must be taken to ensure that the brake shoes are properly installed on their correct side of the vehicle. When the trailing shoes are properly installed on their correct side of the vehicle, the parking brake actuating lever will be positioned under the brake shoe web.

13. Install the parking brake cable onto the parking brake lever, then install the trailing brake shoe and attaching pin.

14. Install the automatic self-adjuster on the leading brake shoe by rotating it inward to attach. Install the leading shoe and adjuster assembly to the brake support plate.

15. Make sure the leading brake shoe is squarely seated on the brake support plate shoe contact areas and install the brake retainer on the retainer pin.

16. Install the lower return spring.

The upper brake shoe return spring and adjuster mechanism actuating spring are unique for each side of the vehicle. The springs are colored for identification. The left side springs are green and the right side springs are blue.

17. Install the upper return spring (blue on right side; green on left side) on the leading brake shoe first, then on the trailing brake shoe.

18. Install the self-adjuster spring on the trailing brake shoe first, then attach it to the adjuster.

19. Install the brake drum.

20. Repeat Steps 3-19 for the other rear wheel's brake assembly.

21. Install the tire and wheel assemblies. Tighten the lug nuts in a star pattern to 95 ft. lbs. (129 Nm).

22. Lower the vehicle.

23. Adjust the rear brakes shoes.

24. Road test the vehicle to check for proper brake operation.

Sebring Convertible

When removing the rear brake shoes, replace the brake shoes from only one side of the vehicle at a time. This is due to the automatic adjustment feature of the parking brake system. If the brake shoes are removed from both sides of the vehicle at the same time, the automatic adjuster will remove all slack from the parking brake cables, which will make brake shoe installation extremely difficult.

1. Raise and safely support the vehicle.

2. Remove the rear wheel assembly.

3. Remove the brake drum from the hub assembly.

Note the location of the automatic adjuster's actuating spring and lever

Click to enlarge

Remove the brake shoe upper return spring

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Remove the brake shoe lower return spring

Click to enlarge4. Remove the adjusting lever actuating spring from the leading brake shoe. Remove the automatic adjuster actuating lever from the leading brake shoe.

5. Thread the adjuster star wheel all the way into the adjuster, which will remove all tension from the adjuster.

6. Remove the upper and lower return springs from the brake shoes.

Remove the leading brake shoe hold-down spring and pin

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Remove the automatic adjuster from the trailing brake shoe

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Remove the parking brake lever-to-trailing brake shoe retaining clip

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Remove the trailing brake shoe

Click to enlarge7. Remove the brake shoe hold-down spring and pin attaching the leading brake shoe assembly to the brake support plate.

8. Remove the leading brake shoe from the support plate.

9. Remove the automatic adjuster from the parking brake actuating lever and trailing brake shoe.

10. Remove the retaining clip securing the parking brake actuating lever to the trailing brake shoe.

11. Remove the trailing brake shoe hold-down spring and pin attaching the trailing brake shoe assembly to the brake support plate.

12. Remove the trailing brake shoe from the brake support plate and separate the shoe from the parking brake actuating lever.

To install:

Lubricate the brake shoe contact areas

Click to enlarge

Install the wave washer onto the pin of the parking brake actuating lever

Click to enlarge13. Lubricate the 6 brake shoe contact points and the brake shoe anchor points with high-temperature grease.

14. Install the wave washer on the pivot pin of the parking brake actuating lever.

15. Install the trailing brake shoe onto the attaching pin of the parking brake actuating lever.

16. Position the trailing brake shoe onto the brake support plate and be sure the trailing brake shoe is squarely seated on the support plate shoe contact areas and install the brake shoe hold-down spring on the hold-down pin.

17. Install the parking brake actuating lever-to-trailing brake shoe retaining clip.

18. Install the automatic adjuster on the trailing brake shoe and the parking brake actuating lever.

19. Place the leading brake shoe onto the brake support plate in proper position and install the attaching pin and hold-down spring.

20. Install the lower and upper return springs.

21. Install the automatic adjuster actuating lever and spring onto the leading brake shoe.

22. Manually adjust the brake shoes to the furthest adjusted position but not so far as to interfere with the installation of the brake drum.

23. Install the brake drums. Check and adjust the brake shoes as necessary.

24. Install the wheel and tire. Tighten the lug nuts in a star pattern to 95 ft. lbs. (129 Nm).

25. Lower the vehicle.

26. Road test the vehicle to check for proper brake operation.

Sebring Coupe and Avenger

1. Raise and safely support the vehicle and remove the wheel assembly.

2. Remove the brake drum.

Note the location of all springs and clips for proper reassembly.

3. Remove the shoe-to-lever spring and remove the adjuster lever.

4. Remove the auto adjuster assembly.

5. Remove the retainer spring.

6. Remove the hold-down springs, washers and pins.

7. Remove the shoe-to-shoe spring.

8. Remove the brake shoes from the backing plate.

9. Using a flat-tipped tool, open up the parking brake lever retaining clip. Remove the clip and washer from the pin on the shoe assembly and remove the shoe from the lever assembly.

To install:

10. Thoroughly clean and dry the backing plate. Lubricate the backing plate at the brake shoe contact points.

11. Lubricate backing plate bosses, anchor pin, and parking brake actuating mechanism with a lithium-based grease.

12. Install the parking brake lever assembly on the lever pin. Install the wave washer and a new retaining clip. Use pliers or the like to install the retainer on the pin. If removed, connect the parking brake lever to the parking brake cable and verify that the cable is properly routed.

13. Clean and lubricate the adjuster assembly. Make sure the nut-adjuster is drawn all the way to the stop, but the nut must NOT lock firmly at the end of the assembly.

14. Install the brake shoes on the backing plate with the hold-down springs, washers and pins.

15. Install the shoe-to-shoe spring.

16. Install the retainer spring.

17. Install the auto adjuster assembly and install the adjuster lever and the shoe-to-lever spring.

18. Pre-adjust the shoes so the drum slides on with a light drag and install the brake drum.

19. Adjust the rear brake shoes and install the rear wheels.

20. Adjust the parking brake cable.

21. Lower the vehicle and check for proper brake operation.

ADJUSTMENTS

Sebring and Avenger

Usually, self-adjusting drum brakes do not necessitate manual adjustment. However, in the event of a brake reline, you should make the initial adjustment to speed up the adjustment period.

1. Make sure the parking brake is fully released.

2. Raise and safely support the vehicle so that all wheels are free to turn.

3. Remove the rear brake adjusting hole rubber plug from the rear of the brake shoe support plate.

4. Insert a suitable brake adjusting tool through the adjusting hole in the support plate and against the star wheel of the adjusting screw. Move the handle of the tool downward until a slight drag is felt when the tire is rotated.

Star wheel type self-adjuster mechanism components-Sebring coupe/convertible and Avenger

Click to enlarge

Backing off the rear brake shoe adjustment

Click to enlarge5. Insert a thin screwdriver or equivalent into the adjusting hole. Push the adjusting lever out of engagement with the star wheel. Be very careful not to bend the adjusting lever or contort the lever spring. While holding the adjusting lever out of engagement with the star wheel, back off the star wheel to guarantee a free wheel with no drag.

6. Repeat the adjustment procedure at the other rear wheel. After the procedure is complete, install the adjusting hole rubber plugs in the rear brake support plates.

7. After adjustment, apply and release the parking brake lever one time.

8. Carefully lower the vehicle.

Cirrus, Stratus and Breeze

1. Adjust the rear brakes by depressing the brake pedal. Brake shoe adjustment will occur the first time the brake pedal is depressed, pushing the rear brake shoes against the braking surface of the brake drums. The brake shoes should now be correctly adjusted and will not require any type of manual adjustment.

Automatic self-adjuster mechanism-Cirrus, Stratus and Breeze

Click to enlargeWheel Cylinders

REMOVAL & INSTALLATION

1. Raise and safely support the vehicle.

2. Remove the rear wheels.

3. Remove the brake drums.

4. Remove the brake shoes. Replace if soaked with grease or brake fluid.

Using a flare nut wrench, loosen the brake line fitting to the wheel cylinder ...

... then unscrew the fitting from behind the wheel cylinder

After removing the mounting bolts, remove the wheel cylinder from the brake backing plate

5. Disconnect and plug the rear brake flex hose from the wheel cylinder.

6. Remove the 2 wheel cylinder attaching bolts.

7. Remove the wheel cylinder from the backing plate.

To install:

8. Apply a small bead of silicone sealer around the mating surface of the backing plate and the wheel cylinder.

9. Position the wheel cylinder on the backing plate and install the 2 wheel cylinder attaching bolts. Tighten the wheel cylinder attaching bolts as follows:

Cirrus, Stratus and Breeze-97 inch lbs. (11 Nm)

Sebring convertible-115 inch lbs. (13 Nm)

Sebring coupe and Avenger-7 ft. lbs. (10 Nm)

10. Hand-start the brake line to the wheel cylinder. Tighten the brake line fitting as follows:

Cirrus, Stratus, Sebring convertible and Breeze-145 inch lbs. (17 Nm)

Sebring coupe and Avenger-11 ft. lbs. (15 Nm)

11. Install the rear brake shoes. Install the brake drum onto the wheel hub.

12. Install the tire and wheel assembly. Tighten in a star pattern to 95 ft. lbs. (129 Nm).

13. Adjust the rear brakes.

14. Bleed the entire brake hydraulic system.

15. Road test the vehicle to check for proper brake operation.

OVERHAUL

Wheel cylinder overhaul kits may be available, but often at little or no savings over a reconditioned wheel cylinder. It often makes sense with these components to substitute a new or reconditioned part instead of attempting an overhaul.

If no replacement is available, or you would prefer to overhaul your wheel cylinders, the following procedure may be used. When rebuilding and installing wheel cylinders, avoid getting any contaminants into the system. Always use clean, new, high quality brake fluid. If dirty or improper fluid has been used, it will be necessary to drain the entire system, flush the system with proper brake fluid, replace all rubber components, then refill and bleed the system.

1. Remove the wheel cylinder from the vehicle and place on a clean workbench.

2. First remove and discard the old rubber boots, then withdraw the pistons. Piston cylinders are equipped with seals and a spring assembly, all located behind the pistons in the cylinder bore.

Remove the outer boots from the wheel cylinder

3. Remove the remaining inner components, seals and spring assembly. Compressed air may be useful in removing these components. If no compressed air is available, be VERY careful not to score the wheel cylinder bore when removing parts from it. Discard all components for which replacements were supplied in the rebuild kit.

Compressed air can be used to remove the pistons and seals

Remove the pistons, cup seals and spring from the cylinder

4. Wash the cylinder and metal parts in denatured alcohol or clean brake fluid.

Use brake fluid and a soft brush to clean the pistons ...

... and the bore of the wheel cylinder

WARNING

Never use a mineral-based solvent such as gasoline, kerosene or paint thinner for cleaning purposes. These solvents will swell rubber components and quickly deteriorate them.

5. Allow the parts to air dry or use compressed air. Do not use rags for cleaning, since lint will remain in the cylinder bore.

6. Inspect the piston and replace it if it shows scratches.

Once cleaned and inspected, the wheel cylinder is ready for assembly

7. Lubricate the cylinder bore and seals using clean brake fluid.

8. Position the spring assembly.

9. Install the inner seals, then the pistons.

Lubricate the cup seals with brake fluid

Install the spring, then the cup seals in the bore

Lightly lubricate the pistons, then install them

10. Insert the new boots into the counterbores by hand. Do not lubricate the boots.

The boots can now be installed over the wheel cylinder ends

11. Install the wheel cylinder.

Chilton Automotive Information Systems. 2004 Thomson Delmar Learning.