Rear Drum Brake

Contents

Rear Brake..........................................................................................................................................3
I. Structure of Rear Brake Assembly ....................................................................................3
II. Replacement of Rear Adjuster Assembly .........................................................................4
III. Replacement of Energy Storage Spring Brake Air Chamber .......................................7
IV. Repair of Rear Brake .....................................................................................................10

1
Front Drum Brake

2
 Rear Drum Brake

Rear Brake
I. Structure of Rear Brake Assembly

1. Plug 10. Rivet 19. Spring washer

2. Lower dust cover 11. Brake friction plate 20. Fastening bolt
3. Roller 12. Brake shoe 21. Bracket assembly
4. Brake bottom plate 13. Brake camshaft 22. Adjusting shim
5. Bushing 14. Large return spring 23. Adjuster assembly
6. Oil seal assembly 15. Brake shoe shaft 24. Axle end circlip
7. Screw 16. Locking wire 25. Fuel nozzle
8. Spring washer 17. Fastening screw 26. Air chamber assembly
9. Upper dust cover 18. Brake shoe spring 27. Cylindrical pin

Structure of Rear Brake Assembly 3

Front Drum Brake

II. Replacement of Rear Adjuster Assembly

(I) Recommended tools and auxiliary materials
Tools and Auxiliary Materials Name and Type

Socket S18/S27, Phillips screwdriver, slip joint

Common tools
pliers

Special tools Special socket for rear hub bearing

Inspection tools Torque wrench (0~750 N·m), feeler gauge

Auxiliary materials Lithium base grease

(II) Operation steps

Removal
1. Fix the wheels.
2. Remove the rear adjuster assembly.

1). Remove the cotter pin and flat head

pin, and separate the pushrod U-fork
from the brake adjuster;

2). Remove the adjuster stop plate and

adjusting shim;
3). Remove the rear adjuster from the rear
brake camshaft.

4 Replacement of Rear Adjuster Assembly

 Rear Drum Brake

Check
1. Check the rear adjuster assembly.
1). The rear adjuster worm shaft can be
rotated freely clockwise and
anticlockwise.
Notice: Replace the rear adjuster
assembly if it can not be rotated freely.

Installation
1. Install the rear adjuster assembly.
1). Apply lithium base grease in the rear
adjuster assembly spline;
2). Install the rear adjuster on rear brake
camshaft;

3). Install the adjuster stop plate and

adjusting shim;
4). Tighten the bolt;
Tightening torque: 40~60 N·m

5). Turn the adjusting bolt of adjuster to

align the hole of the adjuster with that of
U-fork and connect the pushrod U-fork
and brake adjuster.
Notice: ·If necessary, adjust with gaskets
at the both sides of the adjuster and
U-fork to eliminate the lateral force to the
pushrod.

Replacement of Rear Adjuster Assembly 5

Front Drum Brake

2. Adjust the brake clearance.

Refer to Brake Clearance Adjustment.
Standard dimension: 0.3~0.5 mm

Check on Vehicle
1. Start the engine.
Inflate the air reservoir to make sure the air pressure is above 700 kPa.
2. Check the braking performance.
Check the braking process for any seizing, abnormal noise, etc.

6 Replacement of Rear Adjuster Assembly

 Rear Drum Brake

III. Replacement of Energy Storage Spring Brake Air

Chamber
(I) Recommended tools and auxiliary materials
Tools and Auxiliary Materials Name and Type

Double offset ring open-end spanner S21/S24,

Common tools
slip joint pliers

Special tools —

Inspection tool Torque wrench (40~200 N·m), feeler gauge

Auxiliary materials Thread sealant

(II) Operation steps

Removal

1. Fix the wheels.

2. Disconnect the nylon pipe of energy
storage spring brake air chamber.

3. Remove the pipe joint of energy storage

spring brake air chamber.

Replacement of Energy Storage Spring Brake Air Chamber 7

Front Drum Brake

4. Remove the energy storage spring brake

air chamber.
1). Remove the cotter pin and plat head
pin and separate the pushrod U-fork
from the brake adjuster;

2). Remove the fixing nut of energy

storage spring brake air chamber;
3). Take off the energy storage spring
brake air chamber.

Installation
1. Install the energy storage spring brake
air chamber.
1). Fix the energy storage spring brake air
chamber.

Tightening torque: 170~190 N·m

2. Install the pipe joint of energy storage
spring brake air chamber.
1). Wash the thread of pipe joint with
washing agent;
2). Coat a circle of thread from root with
thread sealant, with the coat width no
less than three courses of thread;
3). Install the pipe joint to the energy
storage spring brake air chamber and
make sure the installation position is
correct.

3. Connect the nylon pipe of energy

storage spring brake air chamber.
4. Adjust the brake clearance.
See Brake Clearance Adjustment.
Standard dimension: 0.3~0.5 mm

8 Replacement of Energy Storage Spring Brake Air Chamber

 Rear Drum Brake

Check on Vehicle
1. Start the engine.
Inflate the air reservoir to make sure the air pressure is above 700 kPa.
2. Check the braking performance.

1). Unscrew the air pipe at the inlet 11, pull

up the manual valve, and there shall be
an air pressure input at inlet 11 when
the brake pedal is stepped down;
2). Pull up the manual valve, and there
shall be no air pressure input at inlet 11
when the brake pedal is released;
3). Loose the air pipe at the inlet 12, and
there shall be an air pressure input at
inlet 12 when the brake pedal is
released;
4). Release the manual valve, and there
shall be an air pressure at inlet 12 when
the brake pedal is released.

Replacement of Energy Storage Spring Brake Air Chamber 9

Front Drum Brake

IV. Repair of Rear Brake

(I) Recommended tools and auxiliary materials
Tools and Auxiliary Materials Name and Type

Socket S10/S13/S18/S21/S27, double offset ring

open-end spanner S10, adjustable wrench,
Common tools
Phillips screwdriver, jack, triangle sleeper, crow
bar, slip joint pliers

Special socket for wheel nut, special socket for

Special tools rear hub bearing, special socket for nut
adjustment, special tool for return spring

Inspection tool Torque wrench (0~750 N·m), feeler gauge

Auxiliary materials Lithium base grease

(II) Operation steps

Removal
1. Remove the rear wheel assembly.
1). Block the front and rear sides of front wheels with triangular wood filler blocks.
2). Loose the wheel nuts of rear outside wheel.
3). Support the rear axle with jack until the wheels get off the ground. For the safety,
support underneath the rear axle with a stool.
4). Remove the rear axle wheel assembly.
2. Remove the rear axle shaft.
3. Remove the brake drum and hub assembly.
1). Remove the adjusting nut locking plate.
2). Remove the adjusting nut and use it in removing.
3). Use a hub puller to take off the brake drum and hub assembly.
Notice: Pay special attention to avoid damaging the thread on the axle shaft sleeve
when removing the hub.

10 Repair of Rear Brake

 Rear Drum Brake

4. Remove the brake shoe.

1). Use the special tool for return spring
to remove the return spring.
Notice: Tie the brake shoe with a ring
or iron wire before removing the return
spring.

2). Remove the brake shoe.

3). Remove the locking wire and locating
screw.

4). Remove the support axle pin of brake

shoe and the brake shoe.

5). Remove the elastic retainer ring, roller

pin and roller.

Repair of Rear Brake 11

Front Drum Brake

6). Remove the cotter pin, flat head pin,

washer and spring washer.

12 Repair of Rear Brake

 Rear Drum Brake

5. Remove the nut, air pipe, and the brake

air chamber from its support.

6. Remove the brake adjuster.

1). Remove the elastic retainer ring and
adjuster.

7. Remove the camshaft.

8. Remove the brake air chamber support.

Repair of Rear Brake 13

Front Drum Brake

9. Remove the brake bottom plate and dust

cover.

Check
(The “+” and “-” in the technical parameters of repair limit and wear limit indicate that
corresponding values can be added or subtracted based on the normal dimensions of parts.)

Brake Drum
1. Measure the ID and circumferential
runout of brake drum.
1). ID of brake drum
Wear limit: 4 mm
2). Circumferential runout of brake
drum
Standard dimension: 0~0.15 mm
Wear limit: 0.25 mm
Notice: A thickened friction plate (16
mm) can be used when the ID of
brake drum exceeds the repair limit.
Repair limit: 2 mm

Brake Shoe
1. Measure the thickness of friction plate.
Repair limit: 7~9 mm
Wear limit: 6 mm
Notice: The OD of brake roller is 57 mm.
Notice: Use a new friction plate when the friction plate is worn to repair limit or wear
limit.
2. Measure the ID of brake shoe bushing and the OD of supporting axle pin and then
calculate the clearance between them.
1). OD of supporting axle pin;
Wear limit: -0.2 mm
 ID of bushing:
Wear limit: +0.2 mm

14 Repair of Rear Brake

 Rear Drum Brake

2). Clearance between supporting axle pin and bushing:

Standard dimension: 0.16~0.26 mm
Wear limit: 0.56 mm
3. Measure the ID of brake shoe roller and the OD of roller pin and then calculate the
clearance between them.
1). ID of roller:
Wear limit: +0.4 mm
 OD of roller pin:
Wear limit: -0.4 mm
2). Clearance between roller and roller pin:
Repair standard: 0.09~0.15 mm
Wear limit: 0.4 mm
4. Measure the OD of brake shoe roller.
Wear limit: -0.4 mm

Return Spring
1. Measure the free length of return spring.
Wear limit: +5 mm

Camshaft
1. Measure the OD of the matching part between camshaft and bushing.
Wear limit: -0.3 mm

Camshaft Support
1. Measure the ID of camshaft bushing and calculate the clearance between the
camshaft and bushing.
 ID of camshaft bushing:
Wear limit: +0.3 mm
2. Clearance between camshaft and bushing
Repair standard: 0.35~0.45 mm
Wear limit: 0.7 mm
3. Measure the ID of camshaft bushing at the brake bottom plate and calculate the
clearance between the camshaft and bushing.

Repair of Rear Brake 15

Front Drum Brake

 ID of camshaft bushing:
Wear limit: +0.3 mm

Repair and Replacement

Brake Friction Plate
1. Remove the friction plate rivet.
2. Remove the friction plate.
3. Place a new friction plate on the brake shoe and align it with the rivet hole.

4. Insert the rivet in the brake friction plate

hole and rivet it tightly with a rivet.
Notice: 1. The rivet must fully fill the
riveting hole of brake shoe.
2. There shall be no clearance between
brake shoe and friction plate at the
riveting position (through cutting).
3. There shall be no clearance between
the riveting joint and the countersunk
hole of friction plate.

Brake Shoe Bushing

1. Use a special tool to push out the brake shoe bushing.
2. Remove the dirt in the brake shoe bushing hole.
3. Align the new bushing with its supporting hole and push it into the hole.
Notice: Never apply any lubricating grease or oil on the outer surface of bushing
when installing a new bushing.

16 Repair of Rear Brake

 Rear Drum Brake

Assembling
Assembling Drawing of Rear Brake

1. Brake air chamber 12. Brake shoe friction 23.

2. Brake air chamber plate 24. Spacer sleeve
bracket 13. Return spring 25. Elastic retainer ring
3. Grease nozzle 14. Bolt 26. Brake adjuster
4. Camshaft bushing 15. Return spring 27. Flat head pin
5. Brake bottom plate 16. Brake shoe 28. Cotter pin
6. Oil seal 17. Dust cover 29. Plain washer
7. Camshaft 18. Positioning screw 30. U-fork
8. Rubber plug 19. Locking wire 31. Locking nut
9. Roller 20. Dust cover
10. Elastic retainer ring 21. Supporting pin bushing
11. Roller pin 22. Supporting pin

1. Install the brake bottom plate to the rear

axle shaft sleeve seat.
Tightening torque: 200~250 N·m
Notice: The three bolts at the supporting
pin/camshaft must be thin head ones to
prevent interface with the return spring.

Repair of Rear Brake 17

Front Drum Brake

2. Directly install the brake air chamber

bracket.

3. Install the camshaft.

1). Apply lubricating grease on the inner
chamber of camshaft bushing and
install the camshaft.

2). Adjust the position of brake air chamber

bracket and make sure the camshaft
can be rotated freely, and then fix the
bracket.
Tightening torque: 120~130 N·m

4. Install the camshaft bushing and

adjuster and refit the elastic retainer ring
into place.

18 Repair of Rear Brake

 Rear Drum Brake

5. Install the brake shoe assembly.

1). Install the roller and roller pin to brake
shoe and fix them with elastic retainer
ring and make sure the roller can be
rotated freely.

Notice: Don’t apply lubricating grease

between roller and roller pin.
Notice: 1. Apply lubricating grease in the
oil sump on the inside surface of
bushing.
2. Don’t apply the lubricating grease on
the supporting axle pin.
2). Install the return spring with special tool
for return spring.
Notice: Install one with more spring coils
at the side of the camshaft and another
with less spring coils at the side of the
supporting pin.

3). Align the locating hole of supporting pin

with the locating screw hole in the
brake bottom plate, screw the locating
screw and lock it with locking wire.

6. Install the hub and brake drum assembly.

1). Install the oil seal seat.

Repair of Rear Brake 19

Front Drum Brake

2). Install the hub inner bearing cone.

3). Install the hub outer bearing cup.
4). Tighten the adjusting nut.
5). Measure the pre-tightening force for
hub bearing and allow the hub to be
rotated freely.
6). Install the locking plate to the adjusting
nut and fill up the outside of bearing
with lubricating grease.

7. Install the rear axle shaft.

8. Install the brake air chamber.
1). Install the locking nut and U-fork to the
brake air chamber.
2). Install the brake air chamber.
9. Connect the pushrod U-fork and brake
adjuster.

Check on Vehicle
1. Turn the adjusting bolt of adjuster to
eliminate the clearance between brake
drum and brake friction plate.
2. Turn the adjusting bolt to the left until the
travel of pushrod equals to the standard
repair value. Turn the brake drum to
ensure the clearance consistence.
Repair standard for the travel of
pushrod: 10~45 mm
Notice: Make sure the angle between the
brake air chamber pushrod and adjuster
is 105±5°after adjustment.
3. Install the inner and outer wheel
assemblies.
Tightening torque: 420~490 N·m

20 Repair of Rear Brake