Parking Brake System: Service and Repair

DISASSEMBLY
1. REMOVE REAR WHEEL
Torque: 103 Nm (1.050 kgf-cm, 76 ft. lbs.)





2. REMOVE REAR DISC BRAKE ASSEMBLY
a. Remove the 2 mounting bolts and remove the disc brake assembly.
Torque: 47 Nm (475 kgf-cm, 34 ft. lbs.)
b. Suspend the disc brake securely. Ensure that the hose is not stretched.





3. REMOVE DISC
Release the parking brake lever and remove the disc.

HINT: If the disc cannot be removed easily, turn the shoe adjuster until the wheel turns freely.





4. REMOVE SHOE RETURN SPRINGS
Using needle-nose pliers, remove the shoe return springs.
5. REMOVE FRONT SHOE ADJUSTER AND TENSION SPRING
a. Slide out the front shoe and remove the shoe adjuster.
b. Remove the shoe strut with the spring.
c. Remove the shoe hold-down spring cups, spring and pin.
d. Disconnect the tension spring and remove the front shoe.





6. REMOVE REAR SHOE
a. Slide out the rear shoe.
b. Remove the tension spring from the rear shoe.
c. Remove the shoe hold-down spring cups, spring and pin.
d. Using needle-nose pliers, disconnect the parking brake cable from the parking brake shoe lever.

INSPECTION
1. INSPECT DISASSEMBLED PARTS
Inspect the disassembled parts for wear, rust or damage.
2. MEASURE BRAKE SHOE LINING THICKNESS.
Standard thickness: 2.0 mm (0.079 inch)
Minimum thickness: 1.0 mm (0.039 inch)
3. MEASURE DISC INSIDE DIAMETER.
Standard inside diameter: 170 mm (6.69 inch)
Maximum inside diameter: 171 mm (6.73 inch)
4. INSPECT PARKING BRAKE LINING AND DISC FOR PROPER CONTACT.





5. MEASURE CLEARANCE BETWEEN PARKING BRAKE SHOE AND LEVER
Using a feeler gauge, measure the clearance.
Standard clearance: Less than 0.35 mm (0.0138 inch)





If the clearance is not within the specification, replace the shim with one of the correct size.
6. IF NECESSARY, REPLACE SHIM





a. Using a screwdriver, remove the C-washer and shim.





b. Install the correct size shim with a new C-washer.
c. Remeasure the clearance.

REASSEMBLY
Reassembly is in the reverse order of disassembly.






NOTICE: Apply high temperature grease to the parts indicated by the arrows.

1. ADJUST PARKING BRAKE SHOE CLEARANCE
a. Temporarily install the hub nuts.
b. Remove the hole plug.





c. Turn the adjuster and expand the shoes until the disc locks.
d. Return the adjuster 8 notches.
e. Install the hole plug.
2. SETTLING PARKING BRAKE SHOES AND DISC
a. With the parking brake release button pushed in, pull the lever with 98 N (10 kgf, 22 lbs.) of force.
b. Drive the vehicle at about 50 km/h (31 mph) on a safe, level and dry road for about 400 meters (0.25 mile) in this condition.
c. Repeat this procedure 2 or 3 times.
3. RECHECK AND ADJUST PARKING BRAKE LEVER TRAVEL.