!Guide! Replacing Drum Brake Shoes - MK7 2011

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-Ford Fiesta Zetec JA8  08-13

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Misc:
-You should ALWAYS replace drum brake shoes in pairs (Replacing the adjuster & spring hardware is also a good idea)
-You can buy brake shoe kits that are pre assembled. This makes things a lot easier.

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-Crack off the 19mm wheel nuts for the rear wheels
-Support the rear end of the car with axle stands & chock up one of the front wheels
(THE HANDBRAKE NEEDS TO BE DISENGAGED FOR THIS FULL PROCESS)
-Remove the rear wheels (19mm)

-Remove the 2 T40 torx drum mounting bolts
-Hit the drum 2/3 times from all sides with a rubber mallet to help free up the brake drum
-Fasten an M8 bolt into the drum separation hole, this pulls the drum away from the shoes
-Continue to both pull & hit the drum from all angles until it comes off (Try to get it to work is way off evenly)

-Brush the brake dust away from all of the components. Start from the top & then dislodge the pile that has built up on the bottom lip on the backing plate. (Don't breathe this dust in as it is very bad for your health) (Trap the dust in a tissue or a container & discard of it) (Wear a mask)
-Spray the full brake assembly down with brake cleaner

-Push each wheel cylinder piston in with a screwdriver to make sure that they retract back on their own (Do this with the shoes still installed)
-Take pictures of the full assembly from different points and angles

(IF YOU ARE REPLACING THE SPRINGS THEN YOU CAN OPTIONALLY CUT THEM WITH SMALL BOLT CUTTERS TO MAKE THESE NEXT STEPS EASIER)
-Use a pair of needle nose pliers to remove the adjuster spring from the top & then bottom mounting notch on the adjuster lever & primary shoe
-Use a pair of pliers or a hook tool to remove the top return spring. First unhook the return spring from the primary shoe side.
-Remove both the primary and secondary shoe's brake hold down clip & pin. Do this by tapping the clips free from the pins with a chisel and a hammer.
-Push the pins through & remove them from the backing plate
-Lever the primary shoe towards the front of the vehicle so that you can remove the adjuster lever & adjuster
-Remove the primary shoe from the bottom return spring & also remove the bottom return spring
-Pull the handbrake cable away from the handbrake lever

-Clean up the backing plate with brake cleaner & a wire brush at the 6 brake shoe mounting points. Apply brake grease to these 6 mounting points. Also apply brake grease to the wheel cylinder pistons.
(THE ADJUSTERS HAVE BOTH LEFT & RIGHT HANDED THREAD FOR EACH SIDE OF THE CAR SO DO NOT MIX THEM UP)
-Take a picture of the adjuster so that you have a reference of how it is assembled (If you are reusing it)
-Disassemble the adjuster (If you are reusing it)
-Clean the adjuster, springs, clips, pins with brake cleaner & a wire brush (If you are reusing them)

-Spray copper anti seize on the pivot rivet on the new handbrake lever that is attached to the secondary brake shoe. Work it in at the hinge & then wipe the excess off.
-Hold the end of the handbrake cable with pliers and then force the spring further down the handbrake cable with a pair of snips. 
-Attach the cable to the handbrake lever and allow the spring to snap back into position
-Push the secondary shoe hold down pin through the backing plate and hold it in place with your finger
-Press the hold down clip in with pliers and push it upwards and through the hold down pin to lock it in place

-Spray copper anti seize on the threads of the adjuster and reassemble it so that it is identical to the picture you took (Make sure the keyway lines up with the notches)
-Rest the forked (non adjusting) side of the adjuster in it's mounting point on the secondary shoe

-Hook the bottom return spring to the secondary shoe notch
-Hook the bottom return spring to the primary shoe notch
-Position the primary shoe on the backing plate & seat it between the notch on the adjuster 
-Attach the adjuster lever to the adjuster
-Push the primary shoe hold down pin through the backing plate and hold it in place with your finger
-Press the hold down clip in with pliers and push it upwards and through the hold down pin to lock it in place

-Attach the coiled end of the top return spring to the secondary shoe notch
-With a hooked pic pull the return spring & secure it on the notch on the primary shoe

-Attach the adjuster spring to the bottom notch on the primary shoe (Coiled end of the spring goes towards the bottom of the shoe)
-Pull the top of the adjuster spring with a hooked pic and notch it on the adjuster lever

-Tap the bottom of the brake shoes until they sit flush with the bottom of the anchor plate
-Manipulate the brake shoes until each wheel cylinder piston is equally retracted

-Repeat this process on the other side of the car (Put the brake drums on last so that you can use the now completed side for reference)

-Apply a conservative amount of high temperature copper anti seize to both wheel hub faces (Don't get any on the studs)
-Fit both brake drums back on (Tap them on with a rubber mallet if you need to) (Make sure the torx bolt holes line up)
-If the drum wont fit over the shoes then lift the adjuster lever slightly and manually turn the adjuster screw with a flat screwdriver
-Fasten the 2 T40 torx drum mounting bolts until they are reasonably tight. Do this on both drums.
-Apply a conservative amount of aluminium anti seize to both brake drum mating surfaces (Don't get any on the studs)
-Fasten both wheels back on (19mm)

-Engage the handbrake
-Make sure the wheels can spin at least 1 revolution by hand (Don't worry if it is more than this - If they don't spin for 1+ revolution then you will need to adjust the mechanism via the adjustment screw)
-Lower the car back down
-Torque the 19mm wheel nuts to 110Nm

-Launch the car in reverse & slam on the brakes 3 times (This readjusts the mechanism)
-With the handbrake engaged try to push the car. If you can push the car with the handbrake engaged then readjust the mechanism again.

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Useful sources:

How to Replace Rear Drum Brakes 09-19 Ford Fiesta

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