Rear brake shoes - renewal

Braking system / Rear brake shoes - renewal

Warning: Renew BOTH sets of brake shoes at the same time - NEVER renew the shoes on only one wheel, as uneven braking may result. Note that the dust created by wear of the shoes may contain asbestos, which is a health hazard. Never blow it out with compressed air, and DO NOT inhale any of it. An approved filtering mask should be worn when working on the brakes. DO NOT use petrol or petroleumbased solvents to clean brake parts; use brake cleaner or methylated spirit only.

1 Remove the brake drum (see Section 7).

2 Working carefully, and taking the necessary precautions, remove all traces of brake dust from the brake drum, backplate and shoes.

3 Measure the thickness of the friction material of each brake shoe at several points; if either shoe is worn at any point to the specified minimum thickness or less, all four shoes must be renewed as a set. The shoes should also be renewed if any are fouled with oil or grease; there is no satisfactory way of degreasing friction material, once contaminated.

4 If any of the brake shoes are worn unevenly, or fouled with oil or grease, trace and rectify the cause before reassembly.

5 To renew the brake shoes, continue as follows. If the brake shoes are not worn excessively and all is well, refit the brake drum as described in Section 7.

6 Note the position of the brake shoes and springs, and mark the webs of the shoes, if necessary, to aid refitting.

7 Using a pair of pliers, remove the shoe retainer spring cups by depressing and turning them through 90°. With the cups removed, lift off the springs and withdraw the retainer pins (see illustrations).

5.7a Using pliers, remove the spring cup and spring. . .

5.7b . . . and withdraw the retainer pin from the rear of the backplate

8 Ease the shoes out one at a time from the lower pivot point, to release the tension of the return spring, then disconnect the lower return spring from both shoes. Use a pair of pliers or an adjustable spanner to release the shoes (see illustrations).

5.8a Unhook the shoes from the lower pivot point using an adjustable spanner . . .

5.8b . . . and remove the lower return spring

9 Ease the upper end of both shoes out from their wheel cylinder locations, taking care not to damage the wheel cylinder seals, and disconnect the handbrake cable from the trailing shoe. The brake shoe assembly can then be manoeuvred out of position and away from the backplate. Do not depress the brake pedal until the brakes are reassembled and the drum refitted; wrap a strong elastic band around the wheel cylinder pistons to retain them (see illustrations).

5.9a Note the elastic band (arrowed) used to retain pistons

5.9b Disconnecting the handbrake cable from the trailing shoe

10 Make a note of the correct fitted positions of all components then unhook the upper return spring, and disengage the wedge key spring (see illustrations).

5.10a Prior to dismantling, note the correct fitted location of the shoe components

5.10b Wedge key and spring

11 Unhook the tensioning spring, and remove the pushrod from the trailing shoe, together with the wedge key (see illustrations).

5.11a Unhook the tensioning spring (arrowed). . .

5.11b . . . and remove the pushrod from the trailing shoe

12 Examine all components for signs of wear or damage and renew as necessary. Although linings are available separately (without shoes) from VW dealers, renewal of the shoes complete with linings is to be preferred, unless the necessary skills and equipment are available to fit new linings to the old shoes.

13 Peel back the rubber protective caps, and check the wheel cylinder for fluid leaks or other damage; check that both cylinder pistons are free to move easily. Refer to Section 9, if necessary, for information on wheel cylinder overhaul.

14 Apply a little brake grease to the contact areas of the pushrod and handbrake lever.

15 Hook the tensioning spring into the trailing shoe. Engage the pushrod with the opposite end of the spring and pivot the pushrod into position on the trailing shoe.

16 Fit the wedge key between the trailing shoe and pushrod making sure it is fitted the correct way around.

17 Locate the handbrake lever on the leading shoe in the pushrod, and fit the upper return spring using a pair of pliers.

18 Fit the spring to the wedge key and hook it onto the trailing shoe.

19 Prior to installation, clean the backplate, and apply a thin smear of high-temperature brake grease or anti-seize compound to all those surfaces of the backplate which bear on the shoes, particularly the wheel cylinder pistons and lower pivot’ point. Do not allow the lubricant to foul the friction material.

20 Remove the elastic band from the wheel cylinder and offer up the shoe assembly.

21 Connect the handbrake cable to the handbrake lever and locate the top of the shoes in the wheel cylinder piston slots.

22 Fit the lower return spring to the shoes, then lever the bottom of the shoes onto the bottom anchor.

23 Tap the shoes to centralise them with the backplate, then refit the shoe retainer pins and springs, and secure them in position with the spring cups.

24 Refit the brake drum as described in Section 7.

25 Repeat the above procedure on the remaining rear brake.

26 Once both sets of rear shoes have been renewed, adjust the lining-to-drum clearance by repeatedly depressing the brake pedal.

27 Check and, if necessary, adjust the handbrake as described in Section 14.

28 On completion, check the hydraulic fluid level as described in Chapter 1.

29 New shoes will not give full braking efficiency until they have bedded in. Be prepared for this, and avoid hard braking as far as possible for the first hundred miles or so after shoe renewal.