4 - 8
BRAKES
GEM Service Manual
November 2007
DISASSEMBLY
1. Remove the two screws holding drum to
assembly, remove drum.
2. Remove the spring clips from pins at center of
each shoe, and remove pins.
3. Remove bolt, retaining plate and spacer at
lower pad pivot point.
4. Remove lower spring.
5. Remove upper spring.
6. Lift pads away from wheel cylinder and off the
center locating post.
7. Remove two bolts attaching the wheel cylinder
and park brake actuator return spring.
8. Remove the wheel cylinder, spring and park
brake actuator lever.
ASSEMBLY
1. Replace park brake actuator lever.
2. Position wheel cylinder on backing plate and
attach with mounting bolt furthest from actuator
lever.
3. Position park brake actuator lever spring,
making sure it engages lever and is directly
over mounting hole in wheel cylinder, then
insert last mounting bolt and tighten.
4. Install the lower spring.
5. Position trailing shoe first.
6. Position leading shoe.
NOTE: Make sure the pads properly engage
wheel cylinder pistons.
7. Replace upper spring.
8. Replace shoe retention pins and clips.
9. Replace lower pivot point spacer with narrow
side up, then replace retainer with rounded side
down. Attach with bolt and nut.
10. Install the drum and attach with Allen head
screws.
INSTALLATION
NOTE: Be sure you have the correct (RH or LH)
drum brake assembly
.
1. Install the four 13 mm bolts through the rear
axle end into the spindle on rear of brake
assembly. Tighten bolts to 20 ft-lbs.
2. Using flare nut wrench, attach 17 mm brake line
to wheel cylinder.
3. Insert the parking brake cable into park brake
actuator lever.
4. Insert clevis pin into park brake actuator lever,
making sure park brake cable is engaged
securely with cotter pin.
5. Install the tire and wheel assembly. Tighten the
lug nuts to 65 ft-lbs.
6. Install the hubcap.
7. Bleed the brakes. See Brake Bleeding
instructions in this section.
Summary of Contents for GEM E Series
Page 2: ......
Page 87: ...ELECTRICAL 5 40 November 2007 GEM Service Manual ...
Page 95: ...ELECTRICAL 5 48 November 2007 GEM Service Manual ELECTRICAL OVERVIEW ...
Page 97: ...ELECTRICAL 5 50 November 2007 GEM Service Manual POWER DISTRIBUTION ...
Page 98: ...5 51 ELECTRICAL GEM Service Manual November 2007 CHARGING SYSTEM ...
Page 99: ...ELECTRICAL 5 52 November 2007 GEM Service Manual CHARGING SYSTEM CONTINUED e6S eLXD OPTION ...
Page 100: ...5 53 ELECTRICAL GEM Service Manual November 2007 PARK BRAKE CIRCUIT ...
Page 101: ...ELECTRICAL 5 54 November 2007 GEM Service Manual DC DC CONVERTER ...
Page 102: ...5 55 ELECTRICAL GEM Service Manual November 2007 MAIN CONTACTOR ...
Page 103: ...ELECTRICAL 5 56 November 2007 GEM Service Manual MAIN CONTACTOR CONTINUED e6S eLXD OPTION ...
Page 104: ...5 57 ELECTRICAL GEM Service Manual November 2007 MOTOR CONTROLLER SYSTEM ...
Page 105: ...ELECTRICAL 5 58 November 2007 GEM Service Manual MOTOR CONTROLLER SYSTEM CONTINUED ...
Page 106: ...5 59 ELECTRICAL GEM Service Manual November 2007 DISPLAY RD ...
Page 107: ...ELECTRICAL 5 60 November 2007 GEM Service Manual DISPLAY CONTINUED ...
Page 108: ...5 61 ELECTRICAL GEM Service Manual November 2007 DISPLAY CONTINUED ...
Page 109: ...ELECTRICAL 5 62 November 2007 GEM Service Manual HORN POWER OUTLET ...
Page 110: ...5 63 ELECTRICAL GEM Service Manual November 2007 HEATER ...
Page 111: ...ELECTRICAL 5 64 November 2007 GEM Service Manual DASH FAN ...
Page 112: ...5 65 ELECTRICAL GEM Service Manual November 2007 SECURITY LIGHT BAR ...
Page 113: ...ELECTRICAL 5 66 November 2007 GEM Service Manual AUDIO SYSTEM ...
Page 115: ...ELECTRICAL 5 68 November 2007 GEM Service Manual FRONT LIGHTING EXCEPT NEW YORK ...
Page 116: ...5 69 ELECTRICAL GEM Service Manual November 2007 FRONT LIGHTING NEW YORK ...
Page 117: ...ELECTRICAL 5 70 November 2007 GEM Service Manual REAR LIGHTING EXCEPT NEW YORK ...
Page 118: ...5 71 ELECTRICAL GEM Service Manual November 2007 REAR LIGHTING NEW YORK ...
Page 119: ...ELECTRICAL 5 72 November 2007 GEM Service Manual REAR LIGHTING ...
Page 120: ...5 73 ELECTRICAL GEM Service Manual November 2007 REAR LIGHTING CONTINUED ...
Page 121: ...ELECTRICAL 5 74 November 2007 GEM Service Manual TURN SIGNAL REMINDER CIRCUIT ...
Page 122: ...5 75 ELECTRICAL GEM Service Manual November 2007 WIPER WASHER ...
Page 156: ...7 9 BODY INSTALLATION OF SCUFF GUARDS CONTINUED 10 Finish e4 GEM Service Manual November 2007 ...