my truck is a 1997 f250HD 4x4 with a 5.8L and a 5 speed manual transmission.

about a month ago i had to replace a couple broken wheel studs, and in the process ended up having to do a complete rear brake job. i replaced everything, drums, shoes, springs, self adjusters, and wheel cylanders.

i also noticed that one of the e brake cables was frozen, so i replaced it... that prcess was an ordeal to say the least... it took me several hours to get enough slack to hook up the new cable. i then adusted the brakes and was good to go, or so i thought...

i noticed a couple of days later a burnt brake smell and couldnt figure out what the problem was. eventually i noticed that the rear drivers side drum was getting flaming hot. so a few days ago i noticed a clicking/clunk when i pushed the brake pedal in after first driving in reverse. now i finally have a day off from work, so i pulled the drum, and the only thing i noticed is that the e brake apeared to be partially applied...

but the pedal was all the was up and the cables are all tight. so using a pry bar i got the e brake to let go. but if i push the pedxal down and release it, on this one side only the e brake stays slightly engaged. and again i have to use a prybar to release it. none of the cables are frozen, if i disconect themi can easily move each one both in and out... it almost seems like there isnt enough slack in the system, but i cant seem to find any ajustments to loosen the cables...

I am at my wits end here! i am about to just live without an ebrake...

If you need any more info let me know.

sorry for such a long post!

 

A few things. Stiff/frozen brake lever where it pivots on the brake shoe or weak/broken lever retraction spring or wrong length of new cable fitted or faulty auto adjust mechanism.
All I can think of at present.