TMC Made

REAR DRUM BRAKE (for TMC Made)

COMPONENTS:

DISASSEMBLY

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

1. REMOVE REAR WHEEL
2. DRAIN BRAKE FLUID

NOTICE: Wash the brake fluid off immediately if it comes into contact with any painted surface.





3. REMOVE REAR DRUM BRAKE SUB-ASSEMBLY
(a) Put matchmarks on the rear brake drum sub-assembly and the axle hub.
(b) Release the parking brake lever, and remove the brake drum.

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





(c) 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.
(d) Using an another screwdriver, reduce the brake shoe adjuster by turning the adjusting wheel.





4. REMOVE PARKING BRAKE SHOE STRUT SET LH
(a) Using SST, disconnect the return spring from the brake shoes.
SST 09703-30011

NOTICE: Be careful not to damage the cylinder dust boot.





5. REMOVE FRONT BRAKE SHOE
(a) Using SST, remove the cup, shoe hold-down spring and pin.
SST 09718-00011
(b) Remove the front brake shoe and tension spring.
6. REMOVE PARKING BRAKE SHOE STRUT SET LH





7. REMOVE REAR BRAKE AUTOMATIC ADJUST LEVER LH
(a) Remove the automatic adjust lever torsion spring and automatic adjust lever.





8. REMOVE REAR BRAKE SHOE
(a) Using SST, remove the cup, shoe hold-down spring and pin.
SST 09718-00011





(b) Using a needle-nose pliers, disconnect the parking brake cable No. 3 and remove the rear brake shoe.





9. REMOVE PARKING BRAKE SHOE LEVER LH
(a) Using a screwdriver, remove the C-washer and parking brake shoe lever.





10. REMOVE REAR WHEEL BRAKE CYLINDER ASSEMBLY
(a) Using SST, disconnect the brake line.
SST 09023-00101

HINT: Use a container to catch the brake fluid.

(b) Remove the bolt and wheel cylinder.
11. REMOVE REAR WHEEL CYLINDER CUP KIT
(a) Remove the 2 cylinder boots from the wheel cylinder.
(b) Remove the 2 pistons and compression spring.
(c) Remove the 2 cups from each piston.
12. REMOVE REAR DRUM BRAKE BLEEDER PLUG
(a) Remove the bleeder plug cap and bleeder plug from the wheel cylinder.

REASSEMBLY
1. TIGHTEN REAR DRUM BRAKE BLEEDER PLUG
(a) Temporarily tighten the bleeder plug to the wheel cylinder, and install the bleeder plug cap.





2. INSTALL REAR WHEEL CYLINDER CUP KIT
(a) Apply the lithium soap base glycol grease to the 2 new wheel cylinder cups and the 2 pistons.
(b) Install the 2 wheel cylinder cups to each piston.
(c) Install the compression spring and 2 pistons to the wheel cylinder.
(d) Install the 2 new cylinder dust boots to the wheel cylinder.





3. INSTALL REAR WHEEL BRAKE CYLINDER ASSEMBLY
(a) Install the wheel cylinder with the bolt.
Torque: 9.8 Nm (100 kgf-cm, 87 inch lbs.)
(b) Using SST, connect the brake line.
SST 09023-00101
Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.)





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





5. INSTALL PARKING BRAKE SHOE LEVER LH
(a) Using a needle-nose pliers, install the parking brake shoe lever with a new C-washer.





6. INSTALL REAR BRAKE SHOE
(a) Using a needle-nose pliers, connect the parking brake cable No. 3 to the parking brake shoe lever.





(b) Using SST, install the rear brake shoe, pin, shoe hold-down spring and cup.
SST 09718-00011
7. INSTALL REAR BRAKE SHOE RETURN SPRING
(a) Install the shoe return spring to the brake shoe.





8. INSTALL REAR BRAKE AUTOMATIC ADJUST LEVER LH
(a) Install the automatic adjust lever and automatic adjust lever spring to the front brake shoe.





9. INSTALL PARKING BRAKE SHOE STRUT SET LH
(a) Apply the high temperature grease to the adjusting bolt.





(b) Install the parking brake shoe strut set LH as shown in the illustration.





10. INSTALL FRONT BRAKE SHOE
(a) Install the tension spring to the brake shoes.
(b) Using SST, install the front brake shoe, pin, shoe hold-down spring and cup.
SST 09718-00011





11. INSTALL PARKING BRAKE SHOE STRUT SET LH
(a) Using SST, connect the return spring to each shoe.
SST 09703-30011

NOTICE: Be careful not to damage the wheel cylinder boot.

12. CHECK REAR DRUM BRAKE INSTALLATION
(a) Check that each part is installed properly.





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

If they are not installed correctly, reinstall them as shown in the illustration.
13. INSTALL REAR BRAKE DRUM SUB-ASSEMBLY
(a) Aligning the matchmarks, install the rear brake drum sub-assembly.
14. 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 8 notches.
(d) Install the hole plug.
15. FILL RESERVOIR WITH BRAKE FLUID
16. BLEED MASTER CYLINDER
17. BLEED BRAKE LINE
18. CHECK FLUID LEVEL IN RESERVOIR
19. INSPECT FOR BRAKE FLUID LEAK
20. INSTALL REAR WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
21. INSPECT PARKING BRAKE LEVER TRAVEL
22. ADJUST PARKING BRAKE LEVER TRAVEL