Emergency

Technical Information and Restoration Parts for the 928

Emergency Brake

The emergency brake is set up as a standard band brake inside if the rear discs. Over time and with abuse the bands can wear out. This is often an overlooked part of routine maintenance or even periodic brake jobs.

Many disc brake systems implement the emergency brake as a mechanical part of the rear calipers. When pads are replaced the emergency brakes are also refreshed. The implementation of a band brake system is, while mechanical, a valuable extra safety system. Should the disc brakes fade due to fluid boil there is one extra system that can help stop the car.

Inspection and Adjustment

The brakes can be inspected though the inspection hole on the front surface of the disc. Remove the rear wheels and look for a hole in the disc. Using a light to look through the inspection hole, rotate the disc and observer the thickness on the material on the brake shoe. The shoes are located top and bottom as opposed to side to side and both shoes should be inspected. The material should be a good eighth of an inch thick on both shoes.

Adjustment is made by a star wheel located at the rear of the brakes. Again the access hole can be used to turn the star wheel. With slack in the brake cable the brakes should be adjusted so the disc turns freely with no drag. The emergency brake handle is adjusted from the inside of the car after the drum brakes are adjusted and should move five clicks to fully engaged.

Disassembly

	Remove the rear wheels
	Remove the calipers - two bolts on the back side. Hang calipers with a wire to keep tension off the rubber brake line.
	Remove the two Phillips head screws in the disc to the hub. A number three Phillips screw driver tapped on the end to seat and loosen the screws. Alternatively if they are rusted a little Liquid Wrench and an impact driver.
	Slide the disc off over the lug studs. If it binds on the linings then use the access hole to adjust the star wheel creating additional clearance.
	The bands are held on to the hub with two spring clips - one top and one bottom. Use a screw driver to push in on the springs while twisting. The back of the spring has a hook that should come loose.
	Once the bands are free from the backing they can be stretched apart to release the star wheel and then pulled over the hub to release the cable.
	The cable is attached to a lever that pivots causing the brakes to engage. The pivot is held in place with two slip pins. One in the pivot and one on the cable. These pins slip out and can easily be dropped if care is not taken.
	Inspect the inside of the disc for grooving and the bands for oil and wear before reassembling.

Assembly

	Check contact points on the bands to the hub and apply a little white grease to all contact points.
	Clean the treads on star adjuster and lubricate with a little white grease or anti-seize compound.
	Assemble the bands with the long springs and star wheel and then slide the unit over the axle.
	Assemble the pivot arm with the movable portion to the bottom and slip it into the open side of the band assembly.
	Position the upper band and using a screwdriver push in the top spring clip twisting it until it engages with the backing plate. Repeat on the bottom band.
	Release any tension in the emergency brake handle adjust inside of the car.
	Slide the disc over the brake bands. If it will not slide on easily back the star adjustment off a little. Repeat until the disc slides easily over the bands and spins freely. This is a good time to spin the hub and listen for any noise or play in the rear wheel bearings. Without the disc in place the hub should spin freely and not make any noise.
	Alternatively use the access hole to adjust the brakes tight and then back off until they spin freely and then go two more notches.
	Put the Phillips screws back with a little anti-seize compound.
	Adjust the emergency brake cable for full activation in five clicks.
	Double check to make sure the bands are not dragging in the released position.
	Bolt on the calipers using some blue Loctite and torque to 62 ft. lbs.
	Put the wheels on torque lug nuts to 95 ft. lbs. and go for a ride.

Cable Adjustment

Access to the adjustment for the emergency brake is from the inside of the car immediately behind the handle

	Remove the cover plate. It is held in place with three Phillips screws buried in the carpet.
	Loosen the lock nut on the rear of the bracket.
	Turn the bigger nut forward or backwards until the proper adjustment is obtained. The handle should move five clicks before fully engaged.
	Tighten the locking nut and replace the cover.

Cable Removal

The cable is two pieces that pivots in the center under the transmission. The cable main cable runs from the passenger's side brake to the inside of the car. The drive's side runs from the brake to the pivot point. The cable is held in place with three clamps attached to the cross member. Over time oil and dirt accumulates on the cross member making the attachments difficult to locate.

	Remove both rear emergency brakes per above
	Disconnect the cable from the emergency brake handle inside of the car.
	Remove the three claps holding the cable to the cross member.
	Pull the cable free from each hub. These may be frozen in place from age. A pair of channel locks can be used to loosen the cable from the hub.
	Pull the cable from the inside of the car. The connection to the body can also corrode with age. A pair of vice grips can help brake it free.

To reinstall apply a little grease to all pivot point and the connections to the body. Inspect the boot in the center of the cable. This is a common wear point. One inch shrink tube makes a nice replacement for the boot.