Drum Brake System: Service and Repair

REAR DRUM BRAKE
OVERHAUL

HINT: Overhaul the RH side by the same procedures as the LH side.

1. REMOVE REAR WHEEL
2. DRAIN BRAKE FLUID

NOTICE: Wash the brake fluid off immediately if it attaches to any painted surface.





3. REMOVE REAR BRAKE DRUM SUB-ASSEMBLY
a. Release the parking brake lever, and remove the rear brake drum.

HINT: If the rear brake drum cannot be removed easily, perform the following procedure.

b. Remove the hole plug and insert a screwdriver through the hole in the backing plate, and hold the automatic adjusting lever away from the adjuster.
c. Using another screwdriver, reduce the brake shoe adjuster by turning the adjusting wheel.





4. INSPECT BRAKE DRUM INSIDE DIAMETER
a. Using a brake drum gauge or equivalent, measure the inside diameter of the drum.
Standard inside diameter: 254.0 mm (10.00 inch)
Maximum inside diameter: 256.0 mm (10.08 inch)





5. REMOVE FRONT BRAKE SHOE
a. Using SST, remove the shoe return spring from the front brake shoe.
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b. Using a needle-nose pliers, remove the return spring.





c. Using SST, remove the shoe hold down spring cup, shoe hold down spring and pin.
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d. Remove the parking brake shoe strut LWR.
e. Remove the tension spring and front brake shoe. Remove the automatic adjust lever spring and rear brake automatic adjust lever LH from the front brake shoe.





6. REMOVE REAR BRAKE SHOE
a. Using SST, remove the shoe hold down spring cup, shoe hold down spring and pin.
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b. Using a needle-nose pliers, disconnect the parking brake cable No.3 and remove the rear brake shoe.





c. Using a screwdriver, remove the 2 C-washers, parking brake shoe lever, parking brake reaction lever LH and rear brake strut set.





7. INSPECT REAR DRUM BRAKE SHOE LINING THICKNESS
a. Using a ruler, measure the thickness of the shoe lining.
Standard thickness: 5.0 mm (0.197 inch)
Minimum thickness: 1.0 mm (0.039 inch)
If the lining thickness is at the minimum thickness or less, or if there is severe, uneven wear, replace the brake shoe.





8. INSPECT BRAKE DRUM AND REAR DRUM BRAKE SHOE LINING FOR PROPER CONTACT
a. Apply chalk to the inside surface of the drum, then grind drum on the brake shoe lining to fit.
If the contact between the drum and the shoe lining is improper, repair it using a brake shoe grinder or replace the brake shoe assembly.





9. REMOVE LH, FRONT OR UPPER REAR WHEEL BRAKE CYLINDER ASSEMBLY
a. Using SST, disconnect the brake tube, use a container to catch the brake fluid.
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b. Remove the 2 bolts and rear wheel brake cylinder assembly.
10. REMOVE REAR WHEEL CYLINDER CUP KIT
a. Remove the 2 cylinder dust boots from the rear wheel brake cylinder assembly.
b. Remove the 2 pistons and compression spring.
c. Remove the 2 wheel cylinder cups from each piston.
d. Remove the bleeder plug cap and bleeder plug from the rear wheel brake cylinder assembly.
11. INSPECT BRAKE WHEEL CYLINDER
a. Check the cylinder bore and piston for rust or scoring.





12. INSTALL REAR WHEEL CYLINDER CUP KIT
a. Temporarily tighten the bleeder plug to the wheel cylinder, and install the bleeder plug cap.
b. Apply lithium soap base glycol grease to the 2 new wheel cylinder cups and the 2 pistons.
c. Install the 2 wheel cylinder cups to each piston.
d. Install the compression spring and 2 pistons to the rear wheel brake cylinder.
e. Install the 2 new cylinder dust boots to the rear wheel brake cylinder.





13. INSTALL LH, FRONT OR UPPER REAR WHEEL BRAKE CYLINDER ASSEMBLY
a. Install the rear wheel brake cylinder assembly with the 2 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
b. Using SST, connect the brake tube.
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Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.)





14. APPLICATION HIGH TEMPERATURE GREASE
a. Apply high temperature grease to the shoe attached surface of backing plate.





15. INSTALL REAR BRAKE SHOE
a. Apply high temperature grease to the adjusting bolt.
b. Install the rear brake strut set with the shoe return spring.
c. Using a pliers, install the rear brake strut set, parking brake reaction lever and parking brake shoe lever LH with the 2 new C-washers.





d. Using a needle-nose pliers, connect the parking brake cable No.3 to the parking brake shoe lever LH.





e. Using SST, install the rear brake shoe, pin, shoe hold down spring and shoe hold down spring cup.
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16. INSTALL FRONT BRAKE SHOE
a. Install the rear brake automatic adjust lever LH, automatic adjust lever spring and parking brake shoe strut LWR to the front brake shoe.
b. Using SST, install the front brake shoe, pin, shoe hold down spring and shoe hold down spring cup.
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c. Install the tension spring to the front brake shoe and rear brake shoe.





d. Using a needle-nose pliers, install the return spring.





e. Using SST, install the shoe return spring to the front brake shoe.
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17. CHECK REAR DRUM BRAKE INSTALLATION
a. Check that each part is installed properly.





b. Measure the brake drum inside diameter and the diameter of the brake shoes. Check that difference between the diameter is the correct shoe clearance.
Shoe clearance: 0.5 mm (0.020 inch)

NOTICE: There should be no oil or grease adhering to the friction surfaces of the shoe lining and the drum.

18. INSTALL REAR BRAKE DRUM SUB-ASSEMBLY





19. ADJUST REAR DRUM BRAKE SHOE CLEARANCE
a. Temporarily install the hub nuts.
b. Remove the hole plug, and turn the adjuster and expand the shoe until the drum locks.
c. Using a screwdriver, back off the adjuster 15 notches.
d. Install the hole plug.
20. FILL RESERVOIR WITH BRAKE FLUID
21. BLEED MASTER CYLINDER
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22. BLEED BRAKE LINE
23. CHECK FLUID LEVEL IN RESERVOIR
24. CHECK BRAKE FLUID LEAKAGE
25. INSTALL REAR WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
26. INSPECT PARKING BRAKE PEDAL TRAVEL
27. ADJUST PARKING BRAKE PEDAL TRAVEL