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rear drum problem - stumped!!

Teal68

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I need some Bronco brother and sister help. For some reason the brake pedal is not going down very far, and the rear drum brakes engage so little you can still rotate the tires by hand.

A little background: It's my 68 Bronco, dana 30 front with power disc brake conversion. Ever since installed the pedal has been very firm, but the brakes have never performed as well as other disc brake conversions I've done in the past. Still it was good enough, but the braking has degraded to the point that they build no confidence now and I rely on engine braking to aid in stopping much more now.

Any suggestions???

Thanks,
Tyler
 

DirtDonk

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Are you sure it's just the rears? If it's hard to stop then the fronts might not be working as well as they should either.

Did you install a combination valve, or are you still using the stock H-block?

What size master cylinder piston are you using? Should be between 1" and 1.125" with the smaller one giving you more power, but longer pedal throw. Sounds like you have a bigger piston by how hard and high the pedal is.

When you bled the brakes, did the pedal go smoothly to the floor? Just making sure something is not jammed up mechanically.

Stock rear drums presumably? Ever changed the wheel cylinders? Could they be smaller than normal?

Common things to cause what you describe:
1. Too large of a master cylinder
2. Booster not effective (low vacuum or defective booster)
3. Friction material too hard or semi-metallic requiring too much heat to get working.
4. Contaminated materials with gear oil or brake fluid.
5. Defective proportioning/combination valve
6. Hoses and/or hard lines blocked. Rust, old rubber, etc.
7. Rear drums not adjusted out properly.
8. Tires too large for the brakes.
9. Primary and secondary shoes flip-flopped

that's the list for now. Hopefully someone will have more thoughts. But more information might be good too, so throw out anything you think might be important or not in what was done.

good luck.

Paul
 

DirtDonk

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Regarding #9 above, did you verify that the short shoes were facing the front of the vehicle and the long ones the rear?
Of course, if this was the case you'd still be able to stop the rolling wheel when doing it by hand up in the air. It just would not be effective when rolling on the ground.
But you'd also feel a difference when rolling the wheel forward vs backwards.

Paul
 
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Teal68

Teal68

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Paul,
Sorry for the delayed reply, and thank you for your thoughts. Please see my responses below.

I'll add this....I took the drum off the rear passenger, depressed the brake as hard as possible, and used a piece of wood to hold the brake down. That didn't even spread the shoes an 1/8" of an inch from the pin at the top. Heck, it should have blown the pistons out of the wheel cylinders. I have hardly any pressure in the rear!
Thanks,
Tyler

Are you sure it's just the rears? If it's hard to stop then the fronts might not be working as well as they should either.
- I can't get the fronts to lock up, but they are definitely doing the stopping.

Did you install a combination valve, or are you still using the stock H-block?
- I installed the proportioning valve that came with the disc brake kit from WH. If it matters, is there any chance I was sent a disc/disc instead of disc/drum??

What size master cylinder piston are you using? Should be between 1" and 1.125" with the smaller one giving you more power, but longer pedal throw. Sounds like you have a bigger piston by how hard and high the pedal is.
- I'm not sure, but you may know.....It is the one that came with the power brake kit from WH.

When you bled the brakes, did the pedal go smoothly to the floor? Just making sure something is not jammed up mechanically.
- Best I can remember bleeding was typical. I'm going to try disconnecting the rear line before the flex, and see what kind of flow I have. I'm starting to think the flex line may be compromised on the inside.

Stock rear drums presumably?
- Yes

Ever changed the wheel cylinders?
- I have not changed them, but they look like they have been changed recently. I have had this Bronco 3.5 years. Also, best I can rememer the drum/drum brakes worked as expected before I did the swap.

Could they be smaller than normal?
- They appear correct to me

Common things to cause what you describe:
1. Too large of a master cylinder
- Not sure
2. Booster not effective (low vacuum or defective booster)
- Vacuum is good, and booster stays firm.
3. Friction material too hard or semi-metallic requiring too much heat to get working.
- Shoes still look great with no glazing.
4. Contaminated materials with gear oil or brake fluid.
- Very clean looking
5. Defective proportioning/combination valve
- This could be possible
6. Hoses and/or hard lines blocked. Rust, old rubber, etc.
- I'm feeling like this could be it!
7. Rear drums not adjusted out properly.
- Adjusted properly with slight rub when rotating the tires with brake applied
8. Tires too large for the brakes.
- I have 33's. I have run 35's and even 37's before on other Broncos with the same set up and felt comfortable.
9. Primary and secondary shoes flip-flopped
- They are placed correctly



that's the list for now. Hopefully someone will have more thoughts. But more information might be good too, so throw out anything you think might be important or not in what was done.

good luck.

Paul
 

Timmy390

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Off the top of my head......How old are the rubber lines? Sounds like they have "swollen" due to age and not passing fluid. That would explain the pedal not moving much and the brakes cylinders pistons not moving. No fluid is getting through......

Tim
 
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Teal68

Teal68

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Off the top of my head......How old are the rubber lines? Sounds like they have "swollen" due to age and not passing fluid. That would explain the pedal not moving much and the brakes cylinders pistons not moving. No fluid is getting through......

Tim

I'm thinking this is the problem. Not sure how old the rear flex line is. It looks good on the exterior, but that means nothing.
 

Rustytruck

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Check the wear pads on the backing plates where the shoes rub the backing plates. I have had to weld up those pads and grind smooth again before. Does your brake warning light on the dash stay on. if it does you need to recenter the Brake distribution brake switch.
 

DirtDonk

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I took the drum off the rear passenger, depressed the brake as hard as possible... That didn't even spread the shoes an 1/8" of an inch from the pin at the top.

Well there ya go! That'll narrow it down a lot actually.
You may just have to check for pressure at each junction to see where it stops. If it's not building pressure at the master cylinder you can save a lot of head-scratching.

- I can't get the fronts to lock up, but they are definitely doing the stopping.

But not much it sounds like. While we can't always lock them up you should at least be able to stop confidently on the fronts alone.
Leaning more towards the upper end then. Booster, master, combo valve.

- I installed the proportioning valve that came with the disc brake kit from WH. If it matters, is there any chance I was sent a disc/disc instead of disc/drum??

It does matter, but not that much. Rather than whether it's for discs or drums, it could simply be defective. That's where pressure testing before and after is going to have to be done.
They are not all bad, but it certainly would not be the first time for one to cause trouble.

Regarding what type, when did you purchase? If more than two years ago if you have the rubber boot covering the delay valve, then it's a disc-drum.
If it does not have one, it's a disc/disc.
If it has one, but you purchased it more recently, there's no way to tell (that I know of) other than by the part number etched into the unit.

- I'm not sure, but you may know.....It is the one that came with the power brake kit from WH.

Then it's 1.125" diameter. Normally not a problem in itself when used with a booster. But the lack of pressure at the brakes is the telling tale, and that's not due to the master being too large.

- Best I can remember bleeding was typical. I'm going to try disconnecting the rear line before the flex, and see what kind of flow I have. I'm starting to think the flex line may be compromised on the inside.

Absolutely worth the test. This happens way too often and on any type of vehicle for it to be ignored. If they are original, all the more reason. If they have been replaced at least once, that puts them lower on the list, but still worth checking because there is no rhyme or reason to when one will fail.

- I have not changed them (wheel cylinders), but they look like they have been changed recently. I have had this Bronco 3.5 years. Also, best I can rememer the drum/drum brakes worked as expected before I did the swap.

Ok that's a good sign. It's still possible some debris (possibly from a deteriorating rubber hose for example) got in there and is blocking from inside. Would not hurt to check right down to the bleeder valve itself actually. You can get a clogged bleeder and everything else is fine.
Even though this does not sound like the case, it's still worth narrowing down the variables.

- Vacuum is good, and booster stays firm.

Good vacuum is a good sign, but a firm booster is not necessarily good or bad. Depends on what's making it firm.
If it's firm because the relief valve is not opening properly when you press the pedal, that would be a bad thing.

5. Defective proportioning/combination valve
- This could be possible

Definitely.

7. Rear drums not adjusted out properly.
- Adjusted properly with slight rub when rotating the tires with brake applied

Good too, but now that you know there is little to no pressure at the wheel cylinder, anything going on at the friction surfaces is a moot point right now.

I think you're on the right track. Just have to find out where the pressure is dying.
In my experience with our parts, it's rarely the master cylinder, and we now test every booster so it's very rarely a booster issue. But combination valves continue to be a sore spot. Usually it's a leak out of the delay valve, but in just a couple of cases that I've dealt with, the combination valve kept one customer from being able to bleed the brakes and get a firm pedal, and I don't really remember what the other one was. Just that I sent him a new one.
Let's find that pressure!

Good luck.

Paul
 
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Teal68

Teal68

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Thank you all for your suggestions. It's the rear flex line! I have never had one do this that stopped fluid this direction. In the past it has caused brakes to stay locked or tight. Thanks for opening my eyes that they can be compromised either direction!
Tyler
 
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