Drum Brake System: Service and Repair

REAR BRAKE





COMPONENTS

OVERHAUL

HINT: The overhaul procedure for the RH side is the same as that for the LH side.

1. REMOVE REAR WHEEL
2. DRAIN BRAKE FLUID

NOTICE: Immediately wash off any brake fluid that comes into contact with any painted surfaces.





3. REMOVE REAR BRAKE DRUM SUB-ASSEMBLY
a. Release the parking brake, and remove the rear brake drum.
If the rear brake drum cannot be removed easily, perform the following procedures.
b. Remove the hole plug and insert a screwdriver through the hole into the backing plate, and hold the automatic adjusting lever away from the adjuster.
c. Using another screwdriver, contract the brake shoe by turning the adjusting bolt.
d. Remove the drum gasket from the rear brake drum.





4. CHECK BRAKE DRUM INSIDE DIAMETER
a. Using a brake drum gauge or equivalent, measure the inside diameter of the drum.
Standard inside diameter: 254 mm (10.00 inch)
Maximum inside diameter: 256 mm (10.08 inch)
If the inside diameter is greater than the maximum, replace the brake drum.





5. REMOVE FRONT BRAKE SHOE
a. Using SST, remove the shoe return spring from the front brake shoe.
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b. Using 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.
f. Remove the automatic adjust lever spring and 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.
SST 09718-00010





b. Using 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 and parking brake shoe strut set.





7. CHECK 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 the minimum value or less, or if there is any severe or 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 the brake shoe lining for proper fitting.
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, and use a container to collect the brake fluid as it flows out.
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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 wheel cylinder boots from the rear wheel brake cylinder.
b. Remove the 2 pistons and compression spring.
c. Remove the 2 cylinder cups from each piston.
d. Remove the bleeder plug cap and bleeder plug from the rear wheel brake cylinder.
11. INSPECT REAR WHEEL BRAKE CYLINDER
a. Check the cylinder bore and piston for rust and scoring.





12. INSTALL REAR WHEEL CYLINDER CUP KIT
a. Provisionally tighten the bleeder plug to the rear wheel brake cylinder, and install the bleeder plug cap.
b. Apply lithium soap base glycol grease to 2 new cylinder cups and the 2 pistons.
c. Install the cylinder cup onto each piston.
d. Install the compression spring and 2 pistons onto the rear wheel brake cylinder.
e. Install the 2 new wheel cylinder boots onto 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: 9.5 Nm (97 kgf-cm, 84 inch lbs.)
b. Using SST, connect the brake tube.
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Torque: 15.2 Nm (155 kgf-cm, 11 ft. lbs.)





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





15. INSTALL REAR BRAKE SHOE
a. Apply high temperature grease to the adjusting bolt.





b. Install the parking brake shoe lever LH and parking brake shoe strut set with the shoe return spring onto the rear brake shoe.





c. Using pliers, install the parking brake shoe strut set, parking brake reaction lever and parking brake shoe lever LH with 2 new C-washers.





d. Using 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 automatic adjust lever LH, automatic adjust lever spring and parking brake shoe strut LWR onto the front brake shoe.





b. Using SST, install the front brake shoe, pin, shoe hold down spring and shoe hold down spring cup.
SST 09718-00010





c. Install the tension spring onto the front brake shoe and rear brake shoe.





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





e. Using SST, install the shoe return spring onto the front brake shoe.
SST 09921-00010
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 diameters is the specified 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
a. Install a new drum gasket onto the rear brake drum.
b. Install the rear brake drum.





19. ADJUST REAR DRUM BRAKE SHOE CLEARANCE
a. Provisionally install the hub nuts.
b. Remove the hole plug, and turn the adjuster to expand the shoe until the drum locks.
c. Using a screwdriver, release the adjuster 15 notches.
d. Install the hole plug.
20. FILL RESERVOIR WITH BRAKE FLUID (W/VSC)
21. FILL RESERVOIR WITH BRAKE FLUID (W/O VSC)
22. BLEED MASTER CYLINDER (W/O VSC)
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23. BLEED BRAKE LINE (W/VSC)
24. BLEED BRAKE LINE (W/O VSC)
25. CHECK FLUID LEVEL IN RESERVOIR (W/ VSC)
26. CHECK FLUID LEVEL IN RESERVOIR (W/O VSC)
27. CHECK FOR BRAKE FLUID LEAKAGE
28. INSTALL REAR WHEEL
Torque: 113 Nm (1,152 kgf-cm, 83 ft. lbs.)
29. INSPECT PARKING BRAKE PEDAL TRAVEL (AUTOMATIC TRANSAXLE)
30. INSPECT PARKING BRAKE LEVER TRAVEL (MANUAL TRANSAXLE)
31. ADJUST PARKING BRAKE PEDAL TRAVEL (AUTOMATIC TRANSAXLE)
32. ADJUST PARKING BRAKE LEVER TRAVEL (MANUAL TRANSAXLE)