Drum Brake System: Removal & Installation Chevrolet Sonic I

Removal Procedure

1. Release the park brake.
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-542467-S12591948612013041600000) .
3. Remove the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(ref-542477-S14282548822013041600000) .
4. Remove the brake drum bolt (1).
5. Remove the brake drum (1).
6. If reinstalling the brake drum, use the CH-41013 Rotor Resurfacing Kit to clean the wheel hub flange mating surface of the brake drum of any corrosion.

Installation Procedure

1. Using the CH-42450-A Wheel Hub Resurfacing Kit to clean the wheel hub flange of any corrosion.
2. Adjust the drum brakes. Refer to «Drum Brake Adjustment»(ref-542522-S38358090012013041600000) .
3. Install the brake drum (1).
4. Install the brake drum screw (1) and tighten to 9 N.m (80 lb in).
5. Install the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(ref-542477-S14282548822013041600000) .
6. Apply the brakes 2 or 3 times to seat and center the brake shoes on the brake drum.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-542467-S12591948612013041600000) .
2. Remove the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(ref-542477-S14282548822013041600000) .
3. Remove the brake drum. Refer to «Brake Drum Replacement (J93, J94)»(ref-542522-S12724706952013041600000) .
4. Remove the upper brake shoe return spring (1).
5. Remove brake shoe adjuster (1).
6. Remove the brake shoe adjuster actuator lever (1).
7. Remove the brake shoe hold down spring and cup assemblies (1) by compressing the spring and rotating the assembly 1/4 turn.
8. Remove the hold down spring and cup assembly pins (1).
9. Spread the top of the brake shoe assembly (1) and lift the assembly over the wheel hub.
10. Release the park brake actuator lever from the park brake cable eyelet.
11. Remove the lower brake shoe return spring (1).
12. Inspect the drum brake hardware and replace any components, as necessary. Refer to «Drum Brake Hardware Inspection»(ref-542522-S36839058622013041600000) .

1. Clean the drum brake backing plate of any dirt and debris.
2. Apply a light coat of high temperature brake lubricant to the brake drum backing plate shoe contact surfaces.
3. Install the lower brake shoe return spring (1).
4. Install the park brake actuator lever to the park brake cable eyelet.
5. Spread the top of the brake shoe assembly (1) and lift the assembly over the wheel hub.
6. Position the brake shoe assembly to the drum brake backing plate.
7. Install the hold down spring and cup assembly pins (1).
8. Install the brake shoe hold down spring and cup assemblies (1) by compressing the spring and rotating the assembly 1/4 turn.
9. Install the brake shoe adjuster actuator lever (1).
10. Install brake shoe adjuster (1).
11. Install the upper brake shoe return spring (1).
12. Adjust the drum brakes. Refer to «Drum Brake Adjustment»(ref-542522-S38358090012013041600000) .
13. Install the brake drum. Refer to «Brake Drum Replacement (J93, J94)»(ref-542522-S12724706952013041600000) .
14. Install the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(ref-542477-S14282548822013041600000) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-542467-S12591948612013041600000) .
2. Remove the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(ref-542477-S14282548822013041600000) .
3. Remove the rear wheel speed sensor, if equipped. Refer to «Rear Wheel Speed Sensor Replacement»(ref-542519-S04601522742013041600000) .
4. Remove the rear brake cylinder. Refer to «Rear Brake Cylinder Replacement»(ref-542522-S39635065242013041600000) .
5. Remove the brake shoes. Refer to «Brake Shoe Replacement (J93, J94)»(ref-542522-S20776117672013041600000) .
6. Remove the rear wheel bearing and hub assembly (1). Refer to «Rear Wheel Bearing and Hub Replacement (Drum Brake)»(ref-542521-S09670449122013041600000) , «Rear Wheel Bearing and Hub Replacement (Disc Brake)»(ref-542521-S30977400382013041600000) .
7. Disconnect the front park brake cable from the park brake cable connector (1).
8. Remove the rear brake backing plate (2).
9. If necessary, remove the park brake cable from the rear brake backing plate by compressing the park brake cable locking tab.

1. If removed, install the park brake cable to the rear brake backing plate.
2. Ensure the park brake cable locking tab is fully engaged in the rear brake backing plate.
3. Insert the front park brake cable into the park brake cable connector (1).
4. Install the rear brake backing plate (2).
5. Install the rear wheel bearing and hub assembly (1). Refer to «Rear Wheel Bearing and Hub Replacement (Drum Brake)»(ref-542521-S09670449122013041600000) , «Rear Wheel Bearing and Hub Replacement (Disc Brake)»(ref-542521-S30977400382013041600000) .
6. Install the rear wheel speed sensor, if equipped. Refer to «Rear Wheel Speed Sensor Replacement»(ref-542519-S04601522742013041600000) .
7. Install the rear brake cylinder. Refer to «Rear Brake Cylinder Replacement»(ref-542522-S39635065242013041600000) .
8. Install the brake shoes. Refer to «Brake Shoe Replacement (J93, J94)»(ref-542522-S20776117672013041600000) .
9. Install the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(ref-542477-S14282548822013041600000) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-542467-S12591948612013041600000) .
2. Remove the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(ref-542477-S14282548822013041600000) .
3. Remove the brake drum. Refer to «Brake Drum Replacement (J93, J94)»(ref-542522-S12724706952013041600000) .
4. Remove the upper brake shoe return spring (1).
5. Remove brake shoe adjuster (1).
6. Remove the brake shoe adjuster actuator lever (1).
7. Remove the brake shoe hold down spring and cup assemblies (1) by compressing the spring and rotating the assembly 1/4 turn.
8. Remove the hold down spring and cup assembly pins (1).
9. Spread the top of the brake shoe assembly (1) and lift the assembly over the wheel hub.
10. Release the park brake actuator lever from the park brake cable eyelet.
11. Remove the lower brake shoe return spring (1).
12. Inspect the drum brake hardware and replace any components, as necessary. Refer to «Drum Brake Hardware Inspection»(ref-542522-S36839058622013041600000) .

1. Clean the drum brake backing plate of any dirt and debris.
2. Apply a light coat of high temperature brake lubricant to the brake drum backing plate shoe contact surfaces.
3. Install the lower brake shoe return spring (1).
4. Install the park brake actuator lever to the park brake cable eyelet.
5. Spread the top of the brake shoe assembly (1) and lift the assembly over the wheel hub.
6. Position the brake shoe assembly to the drum brake backing plate.
7. Install the hold down spring and cup assembly pins (1).
8. Install the brake shoe hold down spring and cup assemblies (1) by compressing the spring and rotating the assembly 1/4 turn.
9. Install the brake shoe adjuster actuator lever (1).
10. Install brake shoe adjuster (1).
11. Install the upper brake shoe return spring (1).
12. Adjust the drum brakes. Refer to «Drum Brake Adjustment»(ref-542522-S38358090012013041600000) .
13. Install the brake drum. Refer to «Brake Drum Replacement (J93, J94)»(ref-542522-S12724706952013041600000) .
14. Install the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(ref-542477-S14282548822013041600000) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-542467-S12591948612013041600000) .
2. Remove the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(ref-542477-S14282548822013041600000) .
3. Remove the brake drum. Refer to «Brake Drum Replacement (J93, J94)»(ref-542522-S12724706952013041600000) .
4. Remove the upper brake shoe return spring (1).
5. Remove brake shoe adjuster (1).
6. Remove the brake shoe adjuster actuator lever (1).
7. Inspect the drum brake adjusting hardware and replace any damaged components as necessary. Refer to «Drum Brake Adjusting Hardware Inspection»(ref-542522-S40755974102013041600000) .
8. Disassemble the brake shoe adjuster and thoroughly clean the adjuster screw threads of any corrosion.
9. Apply a light coat of high temperature brake lubricant to the brake shoe adjuster screw threads.

1. Assemble the brake shoe adjuster, setting the adjuster to the fully retracted position.
2. Clean the drum brake backing plate of any dirt and debris.
3. Apply a light coat of high temperature brake lubricant to the brake drum backing plate shoe contact surfaces.
4. Install the brake shoe adjuster actuator lever (1).
5. Install brake shoe adjuster (1).
6. Install the upper brake shoe return spring (1).
7. Adjust the drum brakes. Refer to «Drum Brake Adjustment»(ref-542522-S38358090012013041600000) .
8. Install the brake drum. Refer to «Brake Drum Replacement (J93, J94)»(ref-542522-S12724706952013041600000) .
9. Install the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(ref-542477-S14282548822013041600000) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-542467-S12591948612013041600000) .
2. Remove the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(ref-542477-S14282548822013041600000) .
3. Remove the brake drum. Refer to «Brake Drum Replacement (J93, J94)»(ref-542522-S12724706952013041600000) .
4. Remove the drum brake adjusting hardware. Refer to «Drum Brake Adjusting Hardware Replacement (J93, J94)»(ref-542522-S01293899252013041600000) .
5. Clean the area surrounding the wheel cylinder of dirt and debris.
6. Remove the rear brake cylinder bleeder valve bolt (1) and cap (2).
7. Disconnect the brake pipe fitting (1). Cap the brake pipe fitting to prevent brake fluid loss and contamination.
8. Remove the rear brake cylinder bolts (1).
9. Spread the top of the brake shoes slightly and remove the rear brake cylinder (1).

1. Spread the top of the brake shoes slightly and install the rear brake cylinder (1).
2. Install the rear brake cylinder bolts (1) and tighten to 10 N.m (89 lb in).
3. Connect the brake pipe fitting (1) and tighten to 18 N.m (13 lb ft).
4. Install the rear brake cylinder bleeder valve bolt (1) and tighten to 9 N.m (80 lb in).
5. Install the rear brake cylinder bleeder valve bolt cap (2).
6. Install the drum brake adjusting hardware. Refer to «Drum Brake Adjusting Hardware Replacement (J93, J94)»(ref-542522-S01293899252013041600000) .
7. Adjust the drum brakes. Refer to «Drum Brake Adjustment»(ref-542522-S38358090012013041600000) .
8. Install the brake drum. Refer to «Brake Drum Replacement (J93, J94)»(ref-542522-S12724706952013041600000) .
9. Install the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(ref-542477-S14282548822013041600000) .
10. Bleed the hydraulic brake system. Refer to «Hydraulic Brake System Bleeding (Pressure)»(ref-542508-S07986599582013041600000) , «Hydraulic Brake System Bleeding (Manual)»(ref-542508-S01435631772013041600000) .