Windstar Rear Drum Brakes

[FordDIY]

Decided that at 106,000 miles, it would be a good idea to change the rear drum brake shoes on the Windstar.

Drum brake pads are generally called shoes and disc brakes use pads - or so I was taught......

The drums on the rear of the Windstar are some of the simplest I have ever come across.

Simple - but simple does not mean easy!

First, you need to jack the van up - I did this in the center of the rear axle, and placed a jack stand as far on each end as I could - you should block the front wheels to prevent it from rolling.

Remove the wheels - mine were the 16" aluminum wheels with a center cap that pried off easily with a large flat bladed screwdriver.

Next, remove the drums - they pull right off -

If it did, count your blessings.

If not, check to make sure your parkign brake is not on -

No matter in most cases, this is going to be a challenge.

As the shoes wear, many times they will make a ridge or a lip on the outside of the drum, making it neatly impossible to remove - unless -

You adjust the shoes!

There is a small rubber plug on the upper half of the backing plate, in the middle - you need a brake adjusting tool and something to move the adjuster out of the way.

I used a pick, the kind with a bent end.

Picture would of been nice -



And a view from the inside, giving you an idea of what you need to do - the "star wheel" needs to be rotated up (from the back) to move the shoes in, making the drum easy to remove.



Before the star wheel will turn though, you need to push the adjust out a hair to lift it off the star wheel - the adjuster only allows it to turn one way.

Have I lost you yet?

[FordDIY]

Once you have the drum removed, pat yourself on the back, that is sometimes one of the most frustrating parts of this whole job.

Remember I mentioned the ridge in the drum -



This will need to be removed before it will slide over the new shoes.

You can take them to any number of places to have them "turned", that is the right thing to do, or if you are on a budget, careful and patient, you can grind it off yourself -



Wear eye protection and a dust mask for this, and all facets of this repair.

[FordDIY]

Once you have the drum off, you will have access to the brakes.

Here is a quick diagram of all the parts, my Windstar is a 2001 model, you're may or may not be the same.



I'd suggest spraying the entire assembly down with aerosol brake cleaner.

Save enough to spray any dirt or grease off the new shoes and parts after re-assembly. 2 big cans will be enough.

First, I removed the upper spring with a pair of pliers. Then, the adjuster will slide right off the pin - it fits in a groove, simple.

Sometimes I like to put the old parts on the new parts, where they go, might make it easier for you too.

Next, I removed the hold down spring from the front show, then the star wheel - it is three pieces, one end, a thin washer and the other part. Remember how it is positioned!

Then I moved the front brake shoe forward a bit, then off the lower mount and you can move it easily enough to work the lower spring off without using any tools.

Front is off, piece of cake!

Next, remove the hold down spring from the rear shoe, and rotate the top down - there is a clip holding the parking brake pin into the shoe. You can spread this with a screwdriver or press it off with pliers - I should of taken pictures, I appologize.

Once the clip is off, pull the parking brake arm off and guess what - it is completely disassembled!

[FordDIY]

Re-assembly is the reverse of the instructions above.

When installing the rear shoe on the parking brake arm pin, I used pliers to crimp the clip back on. Be sure it is firmly seated in the groove and that you crimp it all the way - if you think the clip, or any of the hardware, is suspect, replace it.

Now move the rear shoe into position - be extra careful around the rubber dust cap on the wheel cylinder, it is easily damaged.

Install the hold down spring.

The front shoe might provide an extra treat, if you are like someone else, you might of bought the cheaper, um, less expensive shoes and the adjuster pin will need to be installed.



And it does not just slip in - you need to be careful, here are some suggestions.

First, find a socket that fits just barely over the pin, but hits the base. Place the shoe on another socket or in a vice positioned so that when you drive the pin in, it can freely go all the way through.

Take your time, do it right. Do not just beat the pin in, the top may become damaged and the grooves for the adjuster smashed, not a good thing......

Now that you have installed the pin all the way, I "peened" mine with a drift to be sure it did not back out, you need to do something, and anyone with a better idea, please speak up!

Here is where I placed 4 peens to "lock" the pin in place -



OK- Now that the shoe is ready, put it on by installing the lower spring then working the shoe into place - it's going to take a little muscle, hold your mouth just right.

Once it is in place, install the star wheel (after turning it to it's smallest setting, make it shorter, in other words, all the way) and the adjuster - make sure it moves freely, then install the spring.

You may need to press the shoes inward on the top to move the wheel cylinder pistons in, make sure the star wheel is in properly and that it is completely in on both shoes.

Finally, install the last hold down spring - double check all of your work.

Spray it all down with brake cleaner to remove any and all contaminents.

Slide the drum back on, it might be a chore, but if you ground the ridge off, it should go with some effort.

Make sure you reinstalled the little rubber plug you took out to adjust the brakes looser to remove the drum - you can tighten them a bit if they are loose, but generally, they will self adjust themselves pretty quickly.

Install the back wheels, torque the nuts (91 ft/lb?) and test it out!

Carefully test it out - listen for any sounds that something is not right.

And back up and stop a lot, 10 times or more - the brakes adjust when you back up and stop.

I was fairly aggressive with my back up stops.

Hopefully everything went well and your Windstar stops like new again.

And I hope this helped you a little -

Thanks for reading.

[Zxingo]

Steve,

I replaced the wheel cylinders and brake shoes on my 2000 windstar, but I started to notice loud squeaking/chattering sound when I apply the brake as I come to a stop. When I removed the drum, I noticed the brake shoes wearing off unevenly - significant wearing at one end of the brake shoes while the other ends are ok with thin lines going across the pads. I replaced the shoes again, but have the same problem. Any ideas?

Thanks for your reply.

David

[PA3]

I was looking for this same information on a 1999 Windstar. Is this info good for it also?

[mark v]

Very nice write-up, made it a sticky!

[Deathwind]

Originally Posted by Zxingo

Steve,

I replaced the wheel cylinders and brake shoes on my 2000 windstar, but I started to notice loud squeaking/chattering sound when I apply the brake as I come to a stop. When I removed the drum, I noticed the brake shoes wearing off unevenly - significant wearing at one end of the brake shoes while the other ends are ok with thin lines going across the pads. I replaced the shoes again, but have the same problem. Any ideas?

Thanks for your reply.

David

Hey man, just read your post and it sounds like to me that you forgot to loosen the parking brake cable.

Its a cable that leads to the rear wheels and there is an adjuster along the cable. You will have to turn the adjuster until the parking brake cable arm stopper is against the shoe metal. The stopper is a little bit of metal that sticks out on the brake shoe metal. You have to make sure that the parking brake arm stopper is against the metal on both sides of the vehicle otherwise there will be wear and tear on the new pads.

After you have adjusted the parking brake cable make sure to test the parking brake; i.e. engage it, then disengage it and check to see if both sides have the parking brake arm stopper hitting the brake shoe metal.

Hope this helps you.

[Eaglefan]

Originally Posted by Zxingo

Steve,

I replaced the wheel cylinders and brake shoes on my 2000 windstar, but I started to notice loud squeaking/chattering sound when I apply the brake as I come to a stop. When I removed the drum, I noticed the brake shoes wearing off unevenly - significant wearing at one end of the brake shoes while the other ends are ok with thin lines going across the pads. I replaced the shoes again, but have the same problem. Any ideas?

Thanks for your reply.

David

I had this problem too.

Solution for me: I learned this from my local mechanic. Remove the shoes and you will notice two standoffs (bumpouts) on each side. Typically they are very rusty. Simply clean rust off and use a very light coating off some type of thermal grease.
Doing this will prevent the shoes from binding and wearing unevenly, plus eliminate the squeaking/chatter.

GL, good write-up.

[12Ounce]

Originally Posted by PA3

I was looking for this same information on a 1999 Windstar. Is this info good for it also?

Yes, this info is good for the '99. Just did mine this week. I would add that the ABS sensor should be withdrawn from the wheel and allowed to hang out of the way while cleaning/replacing is taking place. The sensor needs to be wiped off before re-installing.

Replacement drums, pistons, shoes, and hardware (including the adjusters) are available from AutoZone. Since brakes are so important and this procedure only comes around every 100k miles or so, why not take the extra precaution?