Drum Brake System: Service and Repair

REAR DRUM BRAKE
REMOVAL





1. INSPECT SHOE LINING THICKNESS
Remove the inspection hole plug, and check the shoe lining thickness through the hole.
If less than minimum, replace the shoes.
Minimum thickness: 1.0 mm (0.039 in.)
2. REMOVE REAR WHEEL
3. REMOVE BRAKE DRUM

HINT: If the brake drum cannot be removed easily, do the following steps.





a. Insert a bent wire or an equivalent through the hole in the brake drum, and hold the automatic adjusting lever away from the adjuster.
b. Using a screwdriver, reduce the brake shoe adjustment by turning the adjuster.

HINT: At the time of installation, align the hub's large hole next to the small hole in the clockwise direction with the drum's plug hole.

4. REMOVE FRONT SHOE





a. Using SST, remove the return spring.
SST 09703-30010





b. Using SST, remove the shoe hold-down spring, 2 cups and pin.
SST 09718-00010
c. Disconnect the anchor spring from the front shoe and remove the front shoe.
d. Remove the anchor spring from the rear shoe.





5. REMOVE REAR SHOE
a. Using SST, remove the shoe hold-down spring, 2 cups and pin.
SST 09718-00010
b. Using a screwdriver, disconnect the parking brake cable from the anchor plate.
c. Using pliers, disconnect the parking brake cable from the lever and remove the rear shoe together with the adjuster.





6. REMOVE ADJUSTER FROM REAR SHOE
a. Remove the adjusting lever spring.
b. Remove the adjuster together with the return spring.





7. REMOVE WHEEL CYLINDER
a. Using SST, disconnect the brake line. Use a container to catch the brake fluid.
SST 09023-00101
Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.)
b. Remove the 2 bolts and the wheel cylinder.
Torque: 10 Nm (100 kgf-cm, 7 ft. lbs.)





8. DISASSEMBLE WHEEL CYLINDER
a. Remove the 2 boots from the wheel cylinder.
b. Remove the 2 pistons and spring from the wheel cylinder.
c. Remove the 2 piston cups from each piston.

INSPECTION
1. INSPECT DISASSEMBLED PARTS
Inspect the disassembled parts for wear, rust or damage.





2. MEASURE BRAKE SHOE LINING THICKNESS
Using a ruler, measure the shoe lining thickness.
Standard thickness: 5.0 mm (0.197 in.)
Minimum thickness: 1.0 mm (0.039 in.)
If the shoe lining is less than the minimum or shows signs of uneven wear, replace the brake shoes.

HINT: If a brake shoe needs replacing, the brake shoes must be replaced as a set.





3. MEASURE BRAKE DRUM INSIDE DIAMETER
Using a brake drum gauge or equivalent, measure the inside diameter of the drum.
Standard inside diameter: 228.6 mm (9.000 in.)
Maximum inside diameter: 230.6 mm (9.079 in.)
If the drum is scored or worn, the brake drum may be lathed to the maximum inside diameter.





4. INSPECT REAR BRAKE LINING AND DRUM FOR PROPER CONTACT
If the contact between the brake lining and drum is improper, repair the lining with a brake shoe grinder, or replace the brake shoe assembly.

INSTALLATION
Installation is in the reverse order of removal.

NOTICE: Apply lithium soap base glycol grease and high temperature grease to the parts indicated by the arrows.

1. CHECK OPERATION OF AUTOMATIC ADJUSTING MECHANISM
a. Move the parking brake lever of the rear shoe back and forth. Check that the adjuster turns.
If the adjuster does not turn, check incorrect installation of the rear brake.
b. Adjust the adjuster length to the shortest possible amount.
c. Install the brake drum.
d. Pull the parking brake lever all the way up until a clicking sound can no longer be heard.





2. CHECK CLEARANCE BETWEEN BRAKE SHOES AND DRUM
a. Remove the brake drum.
b. Measure the brake drum inside diameter and diameter of the brake shoes. Check that the difference between the diameters is the correct shoe clearance.
Shoe clearance: 0.6 mm (0.024 in.)
If incorrect, check the parking brake system.
3. FILL BRAKE RESERVOIR WITH BRAKE FLUID
4. BLEED BRAKE SYSTEM
5. CHECK FOR LEAKS
6. INSTALL REAR WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)