It is the worst design ever. My '02 Z71 has had a problem consistently with this. I have replaced the rotor with hat, pads, all hardware, with no real affect. I've added a stack of washers on the adjustment "splitter" under the drivers door (along the frame rail) which seemed to work best. It's always been an issue. A couple of years ago, I was going to do it "right". I replaced all the cables from the pedal to the drum, all hardware and pads, plus purchased the factory tool to set pad spread... still horrible. Best results I've had were repeatly adjusting the star and fitting rotor/hat on, and backing off adjustment until rotor just clears... I went without for a couple of years, just relying on placing the trans in Park. Come to find out that may have had an impact on why my rear planetary ring gear cracked, so I take it a little more seriously now. Maybe drilling an access hole in the rotor to get to the adjustment star would work? I'll be following this thread to see how others have achieved success.
