Well I thought I had it all sussed out. Replacing complete rears - calipers, rotors, pads and parking brakes. Had some trouble getting the rotors on to test the parking brake install, but in the end, they seemed to go on fine. There was a bit of sticking, which I though was in the cables, but a little jiggling of the rotors and they seemed to release.

Then I mounted the caliper, and the frame of the caliper was hitting the outside rotor surface. To make a long story short, I discovered that the rotor wasn't fully seated when I was testing the parking brakes. If I snug down the rotor with a couple of lug nuts, it pushes in a bit further, and then the parking brake binds it. I can grab the rotor by hand, and with a fair bit of force, I can rotate it forwards, but not backwards.

I'm really surprised that I can get the rotor on almost all the way and have no significant binding by the parking brake, but when I tighten it down the last little bit, it grabs pretty good. I would have thought that the surface of the parking brake shoe was sitting parallel to the axle, and whether the rotor was pushed on 70%, 80%, 90%, 100%, it would grab a similar amount, and not increase drastically between 90 and 100%.

I've seen others talk about notching out either the shoe or the metal plate to give more clearance, or do you think that if I can turn the rotor by hand (albeit with more than just a little force) that I can put this together and it will wear the shoe in quickly so that this is not an issue?

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David Armstrong - '86 240(350k km?), '93 940T(270k km), '89 240(parts source for others) near Toronto