Buick Encore: Repair instructions

Brake drum replacement

Special Tools

• CH-41013 Rotor Resurfacing Kit
• CH-42450-A Wheel Hub Resurfacing Kit

For equivalent regional tools, refer to Special Tools.

Removal Procedure

WARNING: Refer to Brake Dust Warning .

1. Release the park brake.
2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
3. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .

Fig. 6: Brake Drum Bolt

4. Remove the brake drum bolt (1).

Fig. 7: Brake Drum

5. Remove the brake drum (1).
6. If reinstalling the brake drum, use the CH-41013 rotor resurfacing kit to clean the wheel hub flange mating surface of the brake drum of any corrosion.

Installation Procedure

1. Using the CH-42450-A wheel hub resurfacing kit to clean the wheel hub flange of any corrosion.
2. Adjust the drum brakes. Refer to Drum Brake Adjustment.

Fig. 8: Brake Drum

3. Install the brake drum (1).

Fig. 9: Brake Drum Bolt

CAUTION: Refer to Fastener Caution .

4. Install the brake drum screw (1) and tighten to 9 (80 lb in).
5. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
6. Apply the brakes 2 or 3 times to seat and center the brake shoes on the brake drum.

Brake drum refinishing

Special Tools

• CH-41013 Rotor Resurfacing Kit
• CH-42450-A Wheel Hub Resurfacing Kit

For equivalent regional tools, refer to Special Tools.

WARNING: Refer to Brake Dust Warning .

1. The brake drums do not require refinishing as part of routine brake system service. Do not refinish brake drums in an attempt to correct the following conditions:

• Brake system noise (squeal, growl, groan)
• Uneven and/or premature brake lining wear
• Superficial or cosmetic corrosion/rust of the brake drum surface
• Scoring of the brake drum surface (less than the maximum allowable specification)

2. Brake drums should only be refinished if the following conditions exist:

• Excessive corrosion/rust and/or pitting
• Cracks and/or heat spots
• Excessive blueing discoloration
• Scoring of the brake drum surface (in excess of the maximum allowable specification)
• Radial runout in excess of the maximum allowable specification

3. Inspect each of the brake drums and determine if the brake drums can be refinished and remain within the maximum allowable diameter after refinish specification:

1. With the tire and wheel assemblies removed, measure the diameter of each of the brake drums.

   Refer to Brake Drum Diameter Measurement.

2. Inspect each of the brake drums for excessive surface wear and/or radial runout. Refer to Brake Drum Surface and Wear Inspection.

4. If the brake drums can be refinished, proceed with the rotor refinishing procedure.
5. If necessary, use the CH-41013 rotor resurfacing kit in order to thoroughly clean any corrosion/rust from the brake drum flange.
6. Mount the brake drum to the brake lathe according to the lathe manufacturer instructions.
7. Ensure that any vibration dampening attachments are securely in place.
8. With the brake lathe running, slowly bring in the cutting tool until it just contacts the brake drum friction surface.
9. Observe the witness mark on the brake drum. If the witness mark extends approximately three-quarters or more of the way around the brake drum surface, the brake drum is properly mounted to the lathe.
10. If the witness mark does not extend three-quarters or more of the way around the brake drum, re-mount the brake drum to the lathe.
11. Following the brake lathe manufacturer instructions, refinish the brake drum.
12. After each successive cut, inspect the brake drum diameter. Refer to Brake Drum Diameter Measurement.
13. If at any time the brake drum exceeds the maximum allowable diameter after refinish specification, the brake drum must be replaced.
14. After refinishing the brake drum, use the following procedure in order to obtain the desired nondirectional finish:

1. Follow the brake lathe manufacturer's recommended speed setting for applying non-directional finish.
2. Using the moderate pressure, apply the non-directional finish:

• If the lathe is equipped with a non-directional finishing tool, apply the finish with 120-grit aluminum oxide sandpaper.
• If the lathe is not equipped with a non-directional finishing tool, apply the finish with a sanding block and 150-grit aluminum oxide sandpaper.

3. After applying a non-directional finish, clean the friction surface of the brake drum with denatured alcohol or an equivalent brake cleaner and wipe the friction surface using a clean shop towel to remove metal particles remaining from machining. Repeat the cleaning process if necessary to remove all metal particles.

15. Remove the brake drum from the brake lathe.
16. If necessary, use the CH-42450-A wheel hub resurfacing kit in order to thoroughly clean any corrosion from the wheel bearing flange.

Brake shoe replacement

Removal Procedure

WARNING: Refer to Brake Dust Warning .

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
3. Remove the brake drum. Refer to Brake Drum Replacement.

Fig. 10: Upper Brake Shoe Return Spring

4. Remove the upper brake shoe return spring (1).

Fig. 11: Brake Shoe Adjuster

5. Remove brake shoe adjuster (1).

Fig. 12: Brake Shoe Adjuster Actuator Lever

6. Remove the brake shoe adjuster actuator lever (1).

Fig. 13: Brake Shoe Hold Down Spring & Cup Assemblies

7. Remove the brake shoe hold down spring and cup assemblies (1) by compressing the spring and rotating the assembly 1/4 turn.

Fig. 14: Brake Shoe Hold Down Spring And Cup Assembly Pins

8. Remove the hold down spring and cup assembly pins (1).

Fig. 15: Brake Shoe Assembly

9. Spread the top of the brake shoe assembly (1) and lift the assembly over the wheel hub.
10. Release the park brake actuator lever from the park brake cable eyelet.

Fig. 16: Lower Brake Shoe Return Spring

11. Remove the lower brake shoe return spring (1).
12. Inspect the drum brake hardware and replace any components, as necessary. Refer to Drum Brake Hardware Inspection.

Installation Procedure

1. Clean the drum brake backing plate of any dirt and debris.
2. Apply a light coat of high temperature brake lubricant to the brake drum backing plate shoe contact surfaces.

Fig. 17: Lower Brake Shoe Return Spring

3. Install the lower brake shoe return spring (1).

Fig. 18: Brake Shoe Assembly

4. Install the park brake actuator lever to the park brake cable eyelet.
5. Spread the top of the brake shoe assembly (1) and lift the assembly over the wheel hub.
6. Position the brake shoe assembly to the drum brake backing plate.

Fig. 19: Brake Shoe Hold Down Spring And Cup Assembly Pins

7. Install the hold down spring and cup assembly pins (1).

Fig. 20: Brake Shoe Hold Down Spring & Cup Assemblies

8. Install the brake shoe hold down spring and cup assemblies (1) by compressing the spring and rotating the assembly 1/4 turn.

Fig. 21: Brake Shoe Adjuster Actuator Lever

9. Install the brake shoe adjuster actuator lever (1).

Fig. 22: Brake Shoe Adjuster

10. Install brake shoe adjuster (1).

Fig. 23: Upper Brake Shoe Return Spring

11. Install the upper brake shoe return spring (1).
12. Adjust the drum brakes. Refer to Drum Brake Adjustment.
13. Install the brake drum. Refer to Brake Drum Replacement.
14. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .

Rear brake backing plate replacement

Removal Procedure

WARNING: Refer to Brake Dust Warning .

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
3. Remove the rear wheel speed sensor, if equipped. Refer to Rear Wheel Speed Sensor Replacement .
4. Remove the brake shoes. Refer to Brake Shoe Replacement.
5. Remove the rear brake cylinder. Refer to Rear Brake Cylinder Replacement.
6. Remove the rear wheel bearing and hub assembly. Refer to Rear Wheel Bearing and Hub Replacement (With Drum Brakes) .

Fig. 24: Park Brake Cable Connector And Backing Plate

NOTE: The park brake cable connector is part of the cable attached to the rear brake backing plate.

7. Disconnect the front park brake cable from the park brake cable connector (1).
8. Remove the rear brake backing plate (2).
9. If necessary, remove the park brake cable from the rear brake backing plate by compressing the park brake cable locking tab.

Installation Procedure

1. If removed, install the park brake cable to the rear brake backing plate.
2. Ensure the park brake cable locking tab is fully engaged in the rear brake backing plate.

Fig. 25: Park Brake Cable Connector And Backing Plate

3. Insert the front park brake cable into the park brake cable connector (1).
4. Install the rear brake backing plate (2).
5. Install the rear wheel bearing and hub assembly. Refer to Rear Wheel Bearing and Hub Replacement (With Drum Brakes) .
6. Install the rear wheel speed sensor, if equipped. Refer to Rear Wheel Speed Sensor Replacement .
7. Install the rear brake cylinder. Refer to Rear Brake Cylinder Replacement.
8. Install the brake shoes. Refer to Brake Shoe Replacement.
9. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .

Drum brake hardware replacement

Removal Procedure

WARNING: Refer to Brake Dust Warning .

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
3. Remove the brake drum. Refer to Brake Drum Replacement

Fig. 26: Upper Brake Shoe Return Spring

4. Remove the upper brake shoe return spring (1).

Fig. 27: Brake Shoe Adjuster

5. Remove brake shoe adjuster (1).

Fig. 28: Brake Shoe Adjuster Actuator Lever

6. Remove the brake shoe adjuster actuator lever (1).

Fig. 29: Brake Shoe Hold Down Spring & Cup Assemblies

7. Remove the brake shoe hold down spring and cup assemblies (1) by compressing the spring and rotating the assembly 1/4 turn.

Fig. 30: Brake Shoe Hold Down Spring And Cup Assembly Pins

8. Remove the hold down spring and cup assembly pins (1).

Fig. 31: Brake Shoe Assembly

9. Spread the top of the brake shoe assembly (1) and lift the assembly over the wheel hub.
10. Release the park brake actuator lever from the park brake cable eyelet.

Fig. 32: Lower Brake Shoe Return Spring

11. Remove the lower brake shoe return spring (1).
12. Inspect the drum brake hardware and replace any components, as necessary. Refer to Drum Brake Hardware Inspection.

Installation Procedure

1. Clean the drum brake backing plate of any dirt and debris.
2. Apply a light coat of high temperature brake lubricant to the brake drum backing plate shoe contact surfaces.

Fig. 33: Lower Brake Shoe Return Spring

3. Install the lower brake shoe return spring (1).

Fig. 34: Brake Shoe Assembly

4. Install the park brake actuator lever to the park brake cable eyelet.
5. Spread the top of the brake shoe assembly (1) and lift the assembly over the wheel hub.
6. Position the brake shoe assembly to the drum brake backing plate.

Fig. 35: Brake Shoe Hold Down Spring And Cup Assembly Pins

7. Install the hold down spring and cup assembly pins (1).

Fig. 36: Brake Shoe Hold Down Spring & Cup Assemblies

8. Install the brake shoe hold down spring and cup assemblies (1) by compressing the spring and rotating the assembly 1/4 turn.

Fig. 37: Brake Shoe Adjuster Actuator Lever

9. Install the brake shoe adjuster actuator lever (1).

Fig. 38: Brake Shoe Adjuster

10. Install brake shoe adjuster (1).

Fig. 39: Upper Brake Shoe Return Spring

11. Install the upper brake shoe return spring (1).
12. Adjust the drum brakes. Refer to Drum Brake Adjustment.
13. Install the brake drum. Refer to Brake Drum Replacement.
14. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .

Drum brake adjusting hardware replacement

Removal Procedure

WARNING: Refer to Brake Dust Warning .

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
3. Remove the brake drum. Refer to Brake Drum Replacement.

Fig. 40: Upper Brake Shoe Return Spring

4. Remove the upper brake shoe return spring (1).

Fig. 41: Brake Shoe Adjuster

5. Remove brake shoe adjuster (1).

Fig. 42: Brake Shoe Adjuster Actuator Lever

6. Remove the brake shoe adjuster actuator lever (1).
7. Inspect the drum brake adjusting hardware and replace any damaged components as necessary. Refer to Drum Brake Adjusting Hardware Inspection.
8. Disassemble the brake shoe adjuster and thoroughly clean the adjuster screw threads of any corrosion.
9. Apply a light coat of high temperature brake lubricant to the brake shoe adjuster screw threads.

Installation Procedure

1. Assemble the brake shoe adjuster, setting the adjuster to the fully retracted position.
2. Clean the drum brake backing plate of any dirt and debris.

Fig. 43: Brake Shoe Adjuster Actuator Lever

3. Install the brake shoe adjuster actuator lever (1).

Fig. 44: Brake Shoe Adjuster

4. Install brake shoe adjuster (1).

Fig. 45: Upper Brake Shoe Return Spring

5. Install the upper brake shoe return spring (1).
6. Adjust the drum brakes. Refer to Drum Brake Adjustment.
7. Install the brake drum. Refer to Brake Drum Replacement.
8. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .

Rear brake cylinder replacement

Removal Procedure

WARNING: Refer to Brake Dust Warning .

WARNING: Refer to Brake Fluid Irritant Warning .

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
3. Remove the brake drum. Refer to Brake Drum Replacement.
4. Remove the drum brake adjusting hardware. Refer to Drum Brake Adjusting Hardware Replacement.
5. Clean the area surrounding the rear brake cylinder of dirt and debris.

Fig. 46: Brake Pipe Fitting

6. Disconnect the brake pipe fitting (1).
7. Cap the brake pipe fitting to prevent brake fluid loss and contamination.

Fig. 47: Rear Brake Cylinder Bolts

8. Remove the rear brake cylinder bolts (1).

Fig. 48: Rear Brake Cylinder

9. Spread the top of the brake shoes slightly and remove the rear brake cylinder (1).

Installation Procedure

Fig. 49: Rear Brake Cylinder

1. Spread the top of the brake shoes slightly and install the rear brake cylinder (1).

Fig. 50: Rear Brake Cylinder Bolts

CAUTION: Refer to Fastener Caution .

2. Install the rear brake cylinder bolts (1) and tighten to 10 (89 lb in).

Fig. 51: Brake Pipe Fitting

3. Connect the brake pipe fitting (1) and tighten to 18 (13 lb ft).
4. Install the drum brake adjusting hardware. Refer to Drum Brake Adjusting Hardware Replacement.
5. Adjust the drum brakes. Refer to Drum Brake Adjustment.
6. Install the brake drum. Refer to Brake Drum Replacement.
7. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
8. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) , Hydraulic Brake System Bleeding (Pressure) .

Rear brake cylinder overhaul

Disassembly Procedure

WARNING: Refer to Brake Dust Warning .

WARNING: Refer to Brake Fluid Irritant Warning .

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Remove the rear brake cylinder. Refer to Rear Brake Cylinder Replacement.

Fig. 52: Brake Cylinder Dust Seals

3. Remove and discard the brake cylinder dust seals (1).

Fig. 53: Brake Cylinder Pistons And Spring

4. Remove the brake cylinder pistons (1) and spring (2).
5. Remove and discard the brake cylinder piston seals.
6. Inspect the brake cylinder bore for excessive corrosion, scoring, nicks, and pitting.
7. If the brake cylinder bore exhibits the above conditions, the brake cylinder assembly requires replacement.
8. Remove light corrosion in the cylinder bore with a fine crocus cloth.
9. Thoroughly clean the brake cylinder and pistons with denatured alcohol and dry with filtered, nonlubricated compressed air.

Assembly Procedure

1. Lightly lubricate the new piston seals and brake cylinder bore with GM approved brake fluid from a clean, sealed, brake fluid container.
2. Assemble the new piston seals with the lip of the seals facing inward to the brake cylinder pistons

Fig. 54: Brake Cylinder Pistons And Spring

3. Install the brake cylinder pistons (1) and spring (2) into the brake cylinder bore.

Fig. 55: Brake Cylinder Dust Seals

NOTE: Do not lubricate the brake cylinder dust seals.

4. Install the new brake cylinder dust seals (1).
5. Install the rear brake cylinder. Refer to Rear Brake Cylinder Replacement.
6. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) , Hydraulic Brake System Bleeding (Pressure) .

Drum brake adjustment

Special Tools

CH-21177-A Drum to Brake Shoe Clearance Gauge

For equivalent regional tools, refer to Special Tools.

WARNING: Refer to Brake Dust Warning

1. Ensure the park brake lever is in the fully released position.
2. Remove the front floor console cupholder insert.

Fig. 56: Parking Brake Cable Adjusting Nut

NOTE: Use ONLY HAND TOOLS when loosening or tightening the adjusting nut.

3. Using ONLY HAND TOOLS, loosen the adjusting nut (1) completely to the end of the front cable threaded rod.
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
5. Remove the rear tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation .
6. Remove the brake drums. Refer to Brake Drum Replacement.

Fig. 57: Installing Drum to Brake Shoe Clearance Gauge Inside Brake Drum Diameter

7. Position the CH-21177-A Drum to Brake Shoe Clearance Gauge to the widest point of the brake drum inside diameter.
8. Firmly hand tighten the set screw on the CH-21177-A Drum to Brake Shoe Clearance Gauge.

Fig. 58: Positioning Drum to Brake Shoe Clearance Gauge Over Brake Shoe Assembly

9. Remove the CH-21177-A Drum to Brake Shoe Clearance Gauge from the brake drum and position it over the corresponding brake shoe assembly at its widest point.
10. While holding the CH-21177-A Drum to Brake Shoe Clearance Gauge in position, insert a proper feeler gauge between one side of the CH-21177-A Drum to Brake Shoe Clearance Gauge , and the corresponding brake shoe lining.
11. Rotate the brake shoe adjuster screw until the brake shoe linings contact the CH-21177-A Drum to Brake Shoe Clearance Gauge and the feeler gauge. Refer to Drum Brake Component Specifications.
12. Repeat the above steps for the opposite brake drum and brake shoe assembly.
13. Install the brake drums. Refer to Brake Drum Replacement.
14. Adjust the park brake. Refer to Parking Brake Adjustment (Drum Brake) .
15. Install the rear tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation .
16. Lower the vehicle.
17. Install the front floor console cupholder insert.

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