Removing brake lever and pivot pin on 2005 roadking

On the bottom of the brake lever pivot pin, there is an "E" clip that needs to be removed.
Once that's done, the pivot pin should push up from the bottom, releasing the lever.

BE CAREFUL, especially when reinstalling.
There is a little "nub" for the front brake light switch (that operates/is pushed by the brake lever) that could break off if care isn't used.
If this happens, your brake light will be on all the time whenever the ignition is turned on.

If I'm thinking about the right thing, the clevis that is attached to the rear brake lever that the rod that goes to the rear brake master cylinder connects to, the clevis should have a pin connecting it to the rear brake lever. On the backside of the pin is either a cotter pin or a circlip holding the pin in. You may have to take the rear brake lever off to access the circlip or cotter pin.

Good Luck
Steve

Are you sure the brake is not releasing? Disc brake pads do not pull back from the disc like drum brake shoes pull back from the drum. They hold a slight contact with the disc to keep dirt and water off the disc and the pads. That's why disc brakes work so much better than drum brakes in wet conditions. I suspect that your brake lever and the pivot pin are worn and need replacing. How much up and down movement does the lever have? The plunger in the brake master cylinder pushes the lever back but the lever operates the front brake light switch. If the lever and it's pivot pin are worn, the lever will not come back far enough to depress the switch.

Good Luck
Steve

There is a silver pivot pin that goes thru the control and lever, remove the c clip from the bottom of the pin and pusu it out. After that the lever is free to be removed.

REMOVAL & INSTALLATION Light Duty Systems Fig. 1: Light duty brake system components

1. Raise and support the vehicle and remove the wheel and brake drum from the wheel to be worked on. NOTE: If you have never replaced the brakes on a van before and you are not too familiar with the procedures involved, only dissemble and assemble one side at a time, leaving the other side intact as a reference during reassembly.
   
2. Install a clamp over the ends of the wheel cylinder to prevent the pistons of the wheel cylinder from coming out, causing loss of fluid and much grief.
3. Contract the brake shoes by pulling the self-adjusting lever away from the starwheel adjustment screw and turn the starwheel up and back until the pivot nut is drawn onto the starwheel as far as it will come.
4. Pull the adjusting lever, cable and automatic adjuster spring down and toward the rear to unhook the pivot hook from the large hole in the secondary shoe web. Do not attempt to pry the pivot hook from the hole.
5. Remove the automatic adjuster spring and the adjusting lever.
6. Remove the secondary shoe-to-anchor spring with a brake tool. (Brake tools are very common implements and are available at auto parts stores). Remove the primary shoe-to-anchor spring and unhook the cable anchor. Remove the anchor pin plate. Fig. 2: Use an appropriate tool to disengage the retracting springs
   
   

1. Raise and support the vehicle.
2. Remove the wheel and drum. Fig. 4: Common heavy duty drum brake assembly
   Fig. 5: Remove the brake drum from the rear axle
   Fig. 6: Remove the parking brake lever retaining nut, located behind the backing plate
   
   
4. Fig. 7: Disconnect the adjusting cable from the anchor pin, cable guide and lever
   Fig. 8: Slide the parking brake lever out from its mounting
   Fig. 9: Disconnect the parking brake cable from the lever
   Fig. 10: Use an appropriate tool to disconnect the return springs from their retaining holes
   Fig. 11: Disengage the hold-down springs from the retaining clips on the backing plate
   Fig. 12: Back off the adjusting screw and remove it from the brake assembly
   Fig. 13: Spread the shoes apart and remove them from the backing plate
   
   

Brake Shoes Removal & Installation Duo-Servo Type To Remove:

1. Raise the vehicle and support it safely.
2. Remove the tire and wheel assembly.
3. Remove the brake drums.
4. Using a brake tool, remove the shoe return springs.
5. Remove the shoe guide.
6. Remove the hold-down springs and pins.
7. Remove the actuator lever and pivot.
8. Remove the lever return spring.
9. Remove the actuator link, parking brake strut, spring retaining ring.
10. Remove the parking brake lever and washer.
11. Remove the shoe assemblies.
12. Remove the adjuster screw and spring from the shoe assembly.

To Install:

1. Use brake cleaning fluid to remove dirt from the brake drum. Check the drums for scoring, cracks and for out-of-round; service the drums as necessary.
2. Check the wheel cylinders by carefully pulling the lower edges of the wheel cylinder boots away from the cylinders. If there is excessive leakage, the inside of the cylinder will drip fluid; repair or replace as necessary.
3. Check the flange plate, which is located around the axle, for leakage of differential lubricant.
4. Lightly lubricate the parking brake cable, parking brake lever where it enters the shoe and the backing plate-to-shoe contact points. Use high temperature, waterproof, grease or special brake lube.
5. Install the parking brake lever into the secondary shoe with the attaching bolt, spring washer, lockwasher, and nut. It is important that the lever move freely before the shoe is attached. Move the assembly and check for proper action.
6. Lubricate the adjusting screw and make sure it works freely.
7. Connect the adjuster screw and spring to the bottom portion of both shoes. Ensure the spring does not interfere with the adjuster rotation when installed. The primary (smaller shoe pad area) to the front and secondary shoe (larger shoe pad area) to the rear of the vehicle.
8. Install the shoe assembly. Ensuring the shoe webs are positioned correctly against the wheel cylinder.
9. Install the parking brake cable.
10. Secure the primary shoes with the hold-down pin and spring.
11. Install the parking brake strut and the strut spring.
12. Install the actuator lever and pivot, securing the assembly with the hold-down pin and spring. Install the actuator link and spring.
13. Install the return springs.
14. Check the operation of the self-adjusting mechanism by moving the actuating lever by hand.
15. Adjust the brakes and install the drum.
16. Adjust the parking brake.
17. Install the tire and wheel assembly.
18. Lower the vehicle.

Leading-Trailing Type To Remove:

1. Raise the vehicle and support it safely.
2. Remove the tire and wheel assembly.
3. Remove the brake drums.
4. Raise the lever arm of the actuator until the upper end is clear of the slot in the adjuster screw.
5. Slide the actuator off the adjuster pin. Disconnect the actuator spring from the shoe.
6. Remove the hold-down spring assemblies and pins.
7. Pull the bottom ends of the shoes apart and lift the lower return spring over the anchor plate. Allow the shoe ends to come together and remove the spring.
8. Remove the shoe assembly, along with the upper return spring and the adjusting screw assembly.
9. Remove the upper return spring and the adjusting screw assembly from the shoes.
10. Remove the retaining ring, pin, spring washer, and parking brake lever.

Typical rear drum brake assembly (Leading/Trailing type)

To Install:

1. Clean adjuster wheel and the backing plates with a suitable cleaner. Lubricate the backing plate contact points, levers and adjuster with a suitable lubricant.
2. Assemble the parking lever, spring washer (concave side facing the brake lever), pin, and retaining ring onto the rearward shoe.
3. Install the adjuster pin in the forward shoe with the pin projecting 0.276 in. (7mm) from the side of the shoe web where the adjuster actuator is installed.
4. With the brake shoes resting on a flat surface (the shoe with the parking lever to the rear of the vehicle), install the upper return spring.
5. Install the adjuster screw assembly with the spring clip facing the backing plate.
6. Place the shoes in position on the backing plate. Do not place the lower shoe webs under the anchor plate.
7. Install the lower return spring, spread the bottom of the shoes and position the shoe against the backing plate.
8. Install the hold-down pins and spring assemblies.
9. Install the adjuster actuator over the end of the adjuster pin so the top leg engages the notch in the adjuster screw.
10. Install the actuator spring, being careful not to over-stretch it more than 3.27 in. (83mm).
11. Install the parking brake cable to the lever.
12. Adjust the parking brake if the shoes will not totally retract.
13. Install the drum, tire and wheel assembly. Adjust the rear brakes and lower the vehicle.

Ford Full-Size Vans 1989-1996 Repair Guide
Brake Shoes - REMOVAL & INSTALLATION

Light Duty Systems

1. Raise and support the vehicle and remove the wheel and brake drum from the wheel to be worked on.

If you have never replaced the brakes on a van before and you are not too familiar with the procedures involved, only dissemble and assemble one side at a time, leaving the other side intact as a reference during reassembly.

1. Install a clamp over the ends of the wheel cylinder to prevent the pistons of the wheel cylinder from coming out, causing loss of fluid and much grief.
2. Contract the brake shoes by pulling the self-adjusting lever away from the starwheel adjustment screw and turn the starwheel up and back until the pivot nut is drawn onto the starwheel as far as it will come.
3. Pull the adjusting lever, cable and automatic adjuster spring down and toward the rear to unhook the pivot hook from the large hole in the secondary shoe web. Do not attempt to pry the pivot hook from the hole.
4. Remove the automatic adjuster spring and the adjusting lever.
5. Remove the secondary shoe-to-anchor spring with a brake tool. (Brake tools are very common implements and are available at auto parts stores). Remove the primary shoe-to-anchor spring and unhook the cable anchor. Remove the anchor pin plate.
   

1. Remove the cable guide from the secondary shoe.
2. Remove the shoe hold-down springs, shoes, adjusting screw, pivot nut, and socket. Note the color of each hold-down spring for assembly. To remove the hold-down springs, reach behind the brake backing plate and place one finger on the end of one of the brake hold-down spring mounting pins. Using a pair of pliers, grasp the washer type retainer on top of the hold-down spring that corresponds to the pin which you are holding. Push down on the pliers and turn them 90° to align the slot in the washer with the head on the spring mounting pin. Remove the spring and washer retainer and repeat this operation on the hold down spring on the other shoe.
3. Remove the parking brake link and spring. Disconnect the parking brake cable from the parking brake lever.
4. After removing the rear brake secondary shoe, disassemble the parking brake lever from the shoe by removing the retaining clip and spring washer.

To install:

1. Assemble the parking brake lever to the secondary shoe and secure it with the spring washer and retaining clip.
2. Apply a light coating of Lubriplate®, or equivalent, at the points where the brake shoes contact the backing plate.
3. Position the brake shoes on the backing plate, and install the hold-down spring pins, springs, and spring washer type retainers. On the rear brake, install the parking brake link, spring and washer. Connect the parking brake cable to the parking brake lever.
4. Install the anchor pin plate, and place the cable anchor over the anchor pin with the crimped side toward the backing plate.
5. Install the primary shoe-to-anchor spring with the brake tool.

1. Install the cable guide on the secondary shoe web with the flanged holes fitted into the hole in the secondary shoe web. Thread the cable around the cable guide groove.
2. Install the secondary shoe-to-anchor (long) spring. Be sure that the cable end is not cocked or binding on the anchor pin when installed. All of the parts should be flat on the anchor pin. Remove the wheel cylinder piston clamp.
3. Apply Lubriplate®, or equivalent, to the threads and the socket end of the adjusting starwheel screw. Turn the adjusting screw into the adjusting pivot nut to the limit of the threads and then back off 1 / 2 turn.

Interchanging the brake shoe adjusting screw assemblies from one side of the vehicle to the other would cause the brake shoes to retract rather than expand each time the automatic adjusting mechanism is operated. To prevent this, the socket end of the adjusting screw is stamped with an "R" or an "L" for "RIGHT" or "LEFT". The adjusting pivot nuts can be distinguished by the number of lines machined around the body of the nut; one line indicates left-hand nut and two lines indicate a right-hand nut.

1. Place the adjusting socket on the screw and install this assembly between the shoe ends with the adjusting screw nearest to the secondary shoe.
2. Place the cable hook into the hole in the adjusting lever from the backing plate side. The adjusting levers are stamped with an R (right) or a L (left) to indicate their installation on the right or left-hand brake assembly.
3. Position the hooked end of the adjuster spring in the primary shoe web and connect the loop end of the spring to the adjuster lever hole.
4. Pull the adjuster lever, cable and automatic adjuster spring down toward the rear to engage the pivot hook in the large hole in the secondary shoe web.
5. After installation, check the action of the adjuster by pulling the section of the cable guide and the adjusting lever toward the secondary shoe web far enough to lift the lever past a tooth on the adjusting screw starwheel. The lever should snap into position behind the next tooth, and release of the cable should cause the adjuster spring to return the lever to its original position. This return action of the lever will turn the adjusting screw starwheel one tooth. The lever should contact the adjusting screw starwheel one tooth above the centerline of the adjusting screw.

If the automatic adjusting mechanism does not perform properly, check the following:

1. Check the cable and fittings. The cable ends should fill or extend slightly beyond the crimped section of the fittings. If this is not the case, replace the cable.
2. Check the cable guide for damage. The cable groove should be parallel to the shoe web, and the body of the guide should lie flat against the web. Replace the cable guide if this is not so.
3. Check the pivot hook on the lever. The hook surfaces should be square with the body on the lever for proper pivoting. Repair or replace the hook as necessary.
4. Make sure that the adjusting screw starwheel is properly seated in the notch in the shoe web.

Heavy Duty Systems

1. Raise and support the vehicle.
2. Remove the wheel and drum.

1. Remove the parking brake lever assembly retaining nut from behind the backing plate and remove the parking brake lever assembly.
2. Remove the adjusting cable assembly from the anchor pin, cable guide and adjusting lever.
3. Remove the brake shoe retracting springs.
4. Remove the brake shoe hold-down spring from each shoe.
5. Remove the brake shoes and adjusting screw assembly.
6. Disassemble the adjusting screw assembly.
7. Clean the ledge pads on the backing plate. Apply a light coat of Lubriplate®, or equivalent, to the ledge pads (where the brake shoes rub the backing plate).

continue...

look under the lever braket for a "C" clip that retains the pivot pin.remove clip,push out pin.assemble in reverse order.

There is a pin at the pivot point of the lever - it is threaded. Unscrew that, pull it out, the old lever will come out easily. Replace with the new one, screw the pivot pin back in - I would put a dab of threadlock on before you screw it in.

If it's a pin at the top, it may be a pivot - some Honda Civics are that way. You remove the lower bolt, and then pivot the caliper up and out of the carrier using the pin as a hinge. Try that - you may have to lever the caliper from the bottom edge using a big screwdriver.