How to Adjust the Rear Brakes on a 1993 Ford Aerostar Van

Ford Motor Company introduced the Ford Aerostar in 1986. When the 1993 Aerostar hit the showroom, it was equipped with either a 3.0-liter V-6 engine or a 4.0-liter V-6 and a choice of two-wheel or four-wheel drive. The front brakes on the 1993 Aerostar are ventilated disc brakes; the rear brakes on both the two-wheel and four-wheel drive models are drum brakes. All of the tools necessary for this project can be found at an auto parts store.

Instructions

1

Remove the torque from the rear wheel lug nuts on the Aerostar, using a tire iron to turn the lug nuts counterclockwise. Raise the rear of the Aerostar using a 2-ton jack or a jack with greater capacity. Place jack stands beneath both ends of the rear axle housing, just inside the rear wheels. Remove the lug nuts completely from both rear wheels with a tire iron, then remove the rear wheels by hand.

2

Remove the brake drum from one side of the Aerostar by hand. Spray 1/2-can of aerosol brake parts cleaner onto the entire set of internal brake components, including the brake shoes and springs. Make sure you also spray the bottom side of the brake components, where you will be working. Visually inspect the rear brake shoes. You should have at least 3/16-inch brake shoe material on the shoes. If you do not have the right amount of shoe material or you notice the shoes are wearing unevenly, replace the brake shoes.

3

Use a flat-head screwdriver on the "star-wheel adjuster" or self-adjuster screw to adjust the rear brake assembly in or out. To tighten the rear brakes, adjust the brake assembly outward. Place the tip of the screwdriver against one of the protruding teeth on the star-like wheel at the bottom of the brake assembly. Push the wheel so that you can see the brakes expanding.

4

Turn the self-adjuster approximately one full turn using the screwdriver. Set the brake drum on the rear brake assembly. You should have about 5 to 7 pounds of resistance when pushing the drum onto the brake assembly. If you receive no resistance, pull the drum off and readjust the self-adjuster 1/2-turn outward. If the brake drum will not go on at all, remove the drum and turn the self-adjuster 1/2-turn inward. Repeat this step until you have the appropriate resistance from the brake shoes on the brake drum during installation of the drum.

5

Repeat Steps 2 through 4 to complete the adjustment on the other side of the Aerostar.

6

Reinstall the rear wheels only when you have visually inspected and verified that both rear drums are firmly pressed onto the wheel hub assembly. This means that the drums need to be pressed onto the rear assembly as far back as they can go. Install the rear wheel lug nuts and snug the lug nuts to the wheel assembly using a tire iron. Raise the rear end of the Aerostar using a 2-ton jack or a jack with greater capacity. Remove the jack stands from beneath the rear axle housing and lower the van to the ground.

7

Tighten the rear wheel lug nuts between 90 and 110 foot-pounds of torque, using a certified torque wrench and wheel nut socket. Do not guess or estimate the amount of torque you put on a wheel lug nut, as this can lead to the wheel falling off during vehicle operation.