This guide provides a general overview. Specific steps might vary slightly depending on your exact Sunfire model and any modifications. Always consult your vehicle's repair manual for precise instructions and torque specifications.
Tools You'll Need:
* Jack and jack stands (safety first! Never work under a car supported only by a jack)
* Lug wrench
* Wheel chocks
* Socket wrench set (metric)
* Ratchet and extensions
* C-clamp or brake caliper compressor tool
* Wire brush
* Brake cleaner
* New brake shoes, springs, and hardware (get a kit – it's usually cheaper and includes everything)
* Pliers
* Torque wrench (essential for proper tightening)
* Safety glasses and gloves
Steps:
1. Safety First: Park on a level surface, engage the parking brake, and chock the front wheels. Raise the rear of the vehicle using the jack and securely support it with jack stands.
2. Remove the Wheel: Loosen the lug nuts slightly before jacking up the car. Remove the wheel and set it aside.
3. Inspect the Brakes: Examine the brake drum, shoes, and hardware for wear and tear. Take note of the spring and adjuster positions for reassembly. You may need to use a hammer and chisel (carefully) to break the drum free from the backing plate if it's rusted or seized.
4. Remove the Brake Drum: Gently tap the drum around its circumference with a rubber mallet to remove it. If it's stuck, you may need to use a drum puller tool.
5. Remove the Brake Shoes: Once the drum is off, you'll see the brake shoes. Note the positions and connections of all springs, clips, and adjusters. Carefully remove the shoes, taking photos or making detailed sketches as you go.
6. Clean: Thoroughly clean the brake drum, backing plate, and shoes with a wire brush and brake cleaner. Ensure everything is free of rust, grease, and debris.
7. Install New Brake Shoes: Carefully install the new brake shoes, springs, and hardware, referencing your notes or photos. Make sure everything is properly seated and aligned. The parking brake mechanism (if applicable) needs to be correctly reconnected.
8. Adjust the Brakes: Many drum brakes have an automatic adjuster, but you may need to manually adjust them after installation. Consult your repair manual for proper adjustment procedure.
9. Install the Brake Drum: Carefully slide the cleaned and re-greased brake drum back onto the axle. It should slide on relatively easily. If it's difficult, you may have something out of alignment.
10. Reinstall the Wheel: Mount the wheel and tighten the lug nuts in a star pattern (opposite nuts, then the ones in between) to the manufacturer's specified torque.
11. Lower the Vehicle: Slowly lower the vehicle and remove the jack stands.
12. Test the Brakes: Carefully test the brakes several times before driving the vehicle. The brake pedal should feel firm. If you have any issues, have the brakes checked by a professional mechanic.
Important Considerations:
* Always use new hardware: Don't reuse old springs, clips, or other hardware.
* Lubricate as needed: Use brake grease where appropriate. Don't use anything that could contaminate the brake surfaces.
* Brake fluid: You should not need to work on the brake fluid lines with this procedure, but check your fluid level after completing the job, just to be safe.
* Torque specifications: Use a torque wrench to tighten lug nuts and other bolts to the manufacturer's specified torque.
This is a general guide, and details may vary. Refer to a repair manual specific to your 2002 Pontiac Sunfire for the most accurate and safe instructions. If you're unsure about any step, consult a professional mechanic. Brake safety is paramount.
