[a4anurag]

With the car crossing 1,19,000 kms, I thought it would be a good idea to change the brake shoes irrespective of their condition as it was neither touched at the ASC and nor did I ever open to check its condition or even for the matter for cleaning it.

Pinged Leoshashi for the part numbers and prices of the items that I intend to replace. After getting them went to MGP stockist and got them. Thank you Sir for the help.

At the same time pinged interc00led, (an integral part of my car maintenance activities) and we fixed a possible date to meet and do this activity near his place.

Meantime, was going through videos on YouTube (especially Chris Fix) for replacing the brake shoes on the car. Videos made it look pretty easy but mind you it is a laborious oriented job.

Tools Needed for the D.I.Y.:

1. Car Jack
   
2. Wheel opening tools
   
3. 3 Ton Jack stand
   
4. 10mm ring spanner
   
5. Hammer
   
6. Flat head screwdriver
   
7. Socket Set
   
8. Pair of gloves
   
9. Sand paper
   
10. Brake Cleaner
    
11. Wire Brushes
    
12. Pieces of rag for cleaning

Images of the Tools needed

[a4anurag]

Brake Drum Assembly and the Brake Shoes

Removal of the drums in some cars is a pain due to rusting mainly, whereby needing a mallet to free it out. In most Maruti Suzuki cars, it has two holes on the drum centre where two bolts need to be screw'ed to free the drum from the hub.

LHS Drum View


LHS handbrake Cable


View from Rear of the LHS Brake Drum


RHS Drum View


RHS Handbrake Cable


View from Rear of the RHS Brake Drum


_________________________ _________________________

Exploded view of the Rear Brake Shoe from the service manual


Part Numbers and Items in the Rear Brake Shoe Assembly

_________________________ _________________________

Parts Cost


_________________________ _________________________


Items that were replaced in this D.I.Y:

Brake Shoes


Shoes were manufactured by - The Frame by KBX and The Brake lining by Rane India


Pin, Shoe Hold down


Retainer, Spring hold down


Spring, Shoe hold down


Spring, Shoe return Lower


Spring, Shoe return Upper


Spring, Strut retaining hold down


Strut Assy, LHS


Strut Assy, RHS


Brake Grease by TVS Girling (heat resistant)


_________________________ _________________________

View of the Rear Hub from top


In the above image, here's what the labelled parts are:

A - Contact points on the backing plate where the shoes move when engaged and disengaged
B - Wheel Cylinder brake fluid line
C - Wheel Cylinder holding nuts
D - Brake fluid bleeder valve and rubber cap
E - Nuts holding the hub and entire assembly
F - Handbrake Cable (with a 10 mm nut)

[a4anurag]

Procedure for the Brake Shoe replacement:

1. Park the car on a flat ground and block the front wheels for safety
   
   
2. Loosen the lug nuts and then raise the car using the jack. Place the Jack stand underneath for additional safety and lower the car so it is secure on the jack stand
   
   
3. Remove the nuts and wheel from the hub assembly
   
   
4. Spray some brake clean and clean the area around the hub and wheel studs. Screw the nuts needed to loosen the drum from the assembly
   
   
5. Slowly tighten the nuts in equal turns till the drum is free from the hub
   
   
6. Cover the brake wheel cylinder and spray liberal amount of brake clean to free out all the brake dust and rust.
   
   
7. Using a 10 mm ring spanner, remove the handbrake cable holding nut and loosen it from the assembly
   
   
8. Using a vice grip pliers, remove the spring that holds the brake shoes. One hand will be needed to rotate the pin from the rear while pressing the spring with the pliers to free the pin from the retainer
   
   
9. Remove the Lower shoe return spring and disconnect the handbrake cable
   
   
10. Once the handbrake is disconnected the two shoes and strut plus upper shoe return spring will come out as a whole unit
    
    
11. Using a flat head screw driver, remove the two springs (Upper shoe return and Strut holding spring).
    
    
12. Using an hammer remove the push nut that holds the handbrake adjuster to the brake shoe.
    
    
13. After this cover the wheel cylinder and thoroughly clean the area and the backing plate. Focus more on the contact points that the shoe move on. After cleaning add a little grease on all the contact points.
    
    
14. Once done, reverse the process to reinstall with newer parts.

[a4anurag]

Here are the images of the D.I.Y:

Couldn't manage to click step-by-step images as hands were dirty

Car raised and jack stand placed


Brake drum


Nuts to open the drum from assembly


Rachet and Bit needed to loosen the drum


Drum removed


As seen after drum is removed (take images so referring it is easy when replacing springs)


Top part of the brake assembly


Bottom part of the brake assembly


Handbrake cable loosened after removing the nut with 10mm spanner


Shoe holding spring, pin and retainer removed


Close up after removing the shoe retaining spring


Shoe return lower spring removed


Older set removed completely


Easy for cleaning


Contact points cleaned (Zoom'ed in)


Handbrake cable holding clip replaced


Drums cleaned and free of rust and brake dust


Older shoes


New Shoes


All parts replaced


_________________________ _________________________

Here's a small video made to show the use of vice grip pliers for securing the shoe retaining spring

http://www.youtube.com/watch?v=bMfKLUbe120

Thanks for reading guys.

[moralfibre]

Thread moved from the Assembly Line to the DIY Section. Thanks for sharing!

Superb thread once again Anurag.

[dhruvritzed]

Absolutely brilliant anurag
I'd like to ask, what exactly is the life of brake shoes in terms of years if you have an idea
My city ivtec automatic is 8 years old but has done only 70000kms, do I need to change them, they usually make a lot of noise when braking during and after rains

[a4anurag]

Originally Posted by dhruvritzed

I'd like to ask, what exactly is the life of brake shoes in terms of years if you have an idea

Mine were healthy enough for another 30-40K kms. Only the one of the two shoes were slightly worn on both sides. But under preventive measures changed both.

Regarding the issue on your car, get it opened and cleaned once. By that you'll know the health of the shoes and also the wheel cylinder condition.

[Keynote]

Originally Posted by a4anurag

With the car crossing 1,19,000 kms, I thought it would be a good idea to change the brake shoes

As always another good DIY from you end. Kudos to both You and interc00led

How do you guys manage to get the right set of tools and equipment to make these DIY's look so easy ? And how much time did it take to complete this mini project?

[a4anurag]

Originally Posted by Keynote

How do you guys manage to get the right set of tools and equipment to make these DIY's look so easy ? And how much time did it take to complete this mini project?

Both of us keep collecting tools. Mostly some tools he has, some I have. We help each other and work together. No point in duplicating tools when both are to be working together, always.

Total time was 2.5 hours for changing the whole setup on both assemblies.

[Dr.Naren]

Good job Anurag!! I am a big fan of your detailed DIY threads

I know that you have done this as a preventive measure. Do you notice any difference in braking now?

[Myth_sx]

Very nicely detailed thread Anurag.

This is quite helpful for someone planning a similar project.
Good set of tools also. :P

Please try to include the sources from where the tools and parts were procured.
Regarding the Rust-Oleum brake cleaner, did you buy it from amazon ?
Can i use it on the disc brake during a regular car wash ?

Just a suggestion. You can include small reviews for certain tools and products used along with their pictures.

Happy DIYing.

[a4anurag]

Originally Posted by Dr.Naren

Do you notice any difference in braking now?

Yes, plus I am heavy user of the handbrake. Use it a lot at traffic signals and whenever parked. Hate to rest my foot on the brake pedal when waiting at the traffic light.

Earlier I had to use both brakes + handbrake. The cable tension adjustment for the handbrake cable under the armrest was half tightened. Have loosened it a bit now post replacement.

Originally Posted by Myth_sx

This is quite helpful for someone planning a similar project. Good set of tools also.

Thank your Sir.

Originally Posted by Myth_sx

Please try to include the sources from where the tools and parts were procured.

1. Car Jack - Provided with the car
2. Wheel opening tools - Provided with the car
3. 3 Ton Jack stand - Bought locally for ₹1,650
4. 10mm ring spanner - Bought it from Amazon IIRC. Don't remember price
5. Hammer & Flat head screwdriver - Had it already
6. Socket Set - From eBay for ₹1,300 almost 3 years back
7. Pair of gloves - Local medical store for ₹ 20 each pair
8. Sand paper - Had it with me. Can be bought from any hardware store
9. Brake Cleaner - From Amazon for ₹411 during sale
10. Wire Brushes - From Amazon for ₹ 116
11. Brake shoes and springs - MGP stockist

Originally Posted by Myth_sx

Regarding the Rust-Oleum brake cleaner, did you buy it from amazon ?

Yes buddy.

Originally Posted by Myth_sx

Can I use it on the disc brake during a regular car wash?

Didn't get this, sorry. Can you explain?

[Myth_sx]

Thank you for the list.

Originally Posted by a4anurag

Didn't get this, sorry. Can you explain?

I meant if its possible to use it as a iron deposit contaminant cleaner. Since one wont be removing the wheel during a regular wash, will this lubricant/cleaner damage any nearby components ?

This is an example of a dedicated iron cleaner but costlier : CarPro Iron X Cleaner

[fighterace]

A job well done, but an overkill. Given the condition of the parts, esp. the lack of rusting, only the shoes needed replacement. That too because precious time had been invested. They still had some life left in them. In fact, if the leading and trailing shoes had been identical, switching the two would have lasted another one lakh km.

More importantly, did you check the wheel cylinders for proper functioning? And when was the brake fluid last replaced and how?

[a4anurag]

Originally Posted by fighterace

And when was the brake fluid last replaced and how?

At 80K IIRC at MASS it was replaced.