Drum Brake System: Service and Repair
REAR DRUM BRAKERear Drum Brake Components:
REMOVAL
HINT:
^ If work that does not involve brake fluid bleeding, such as drum brake shoe replacement, is started 2 minutes or more after the power switch is turned OFF, brake control (ECB) prohibition is not necessary.
1. REMOVE REAR WHEEL
2. SET BRAKE CONTROL (ECB) OFF
NOTICE: Prohibit the brake control (ECB) before bleeding the brake fluid.
a. With the power switch OFF to prohibit brake control, remove the No. 1 and No. 2 motor relays.
NOTICE: If the pump motor operates while there is air remaining inside the brake actuator hose, the air will enter the actuator, resulting in difficulty in air bleeding.
HINT: Brake control (ECB) can be prohibited by selecting "ECB INVALID" on the intelligent tester.
3. DRAIN BRAKE FLUID
NOTICE: Wash brake fluid off immediately if it adheres to any painted surfaces.
4. REMOVE REAR BRAKE DRUM SUB-ASSEMBLY
a. Put matchmarks on the rear brake drum and the axle hub.
b. Release the parking brake and remove the rear brake drum.
HINT: If the rear brake drum cannot be removed, push the rear brake automatic adjust lever through the backing plate service hole using a screwdriver. Turn and contract the adjuster using another screwdriver.
DISASSEMBLY
1. DISCONNECT PARKING BRAKE SHOE STRUT SET
a. Using SST, disconnect the spring and parking brake shoe strut set from the brake shoes.
SST 09703-30011
NOTICE: Be careful not to damage the cylinder dust boot.
2. REMOVE FRONT BRAKE SHOE
a. Using SST, remove the cup, shoe hold down spring and pin.
SST 09718-00010
b. Remove the front brake shoe and tension spring.
3. REMOVE PARKING BRAKE SHOE STRUT SET
a. Remove the parking brake shoe strut set from the rear brake shoe.
4. REMOVE REAR BRAKE AUTOMATIC ADJUST LEVER
a. Remove the rear brake automatic adjust lever tension spring and the rear brake automatic adjust lever.
5. REMOVE REAR BRAKE SHOE
a. Remove the tension spring from the rear brake shoe.
b. Using SST, remove the cup, shoe hold down spring and pin.
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c. Using needle-nose pliers, disconnect the parking brake cable, and remove the rear brake shoe.
6. REMOVE REAR BRAKE PARKING BRAKE SHOE LEVER SUB-ASSEMBLY
a. Using a screwdriver, remove the C-washer and parking brake shoe lever.
7. REMOVE FRONT OR UPPER 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 the rear wheel brake cylinder.
8. REMOVE REAR WHEEL CYLINDER CUP KIT
a. Remove the 2 cylinder dust boots from the rear wheel brake cylinder.
b. Remove the 2 pistons and the compression spring.
c. Remove the 2 wheel cylinder cups from each piston.
9. REMOVE REAR DRUM BRAKE BLEEDER PLUG
a. Remove the rear drum bleeder plug from the rear wheel cylinder.
INSPECTION
1. INSPECT BRAKE DRUM INSIDE DIAMETER
a. Using a brake drum gauge or equivalent, measure the inside diameter of the drum.
Standard inside diameter: 200.0 mm (7.874 inch)
Maximum inside diameter: 201.0 mm (7.913 inch)
HINT: If the inside diameter of the brake drum is at the maximum or more, replace the rear brake drum subassembly.
2. INSPECT REAR DRUM BRAKE SHOE LINING THICKNESS
a. Using a ruler, measure the thickness of the shoe lining.
Standard thickness: 4.0 mm (0.157 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 or uneven wear, replace the brake shoe.
3. 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 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.
4. INSPECT BRAKE WHEEL CYLINDER
a. Check the cylinder bore and the piston for rust or scoring.
If necessary, replace the rear wheel brake cylinder assembly.
REASSEMBLY
1. TEMPORARILY TIGHTEN REAR DRUM BRAKE BLEEDER PLUG
a. Install the rear drum brake bleeder plug to the rear wheel brake cylinder.
2. INSTALL REAR WHEEL CYLINDER CUP KIT
a. Apply lithium soap base glycol grease to 2 new wheel cylinder cups and 2 pistons.
b. Install the 2 wheel cylinder cups on each piston.
c. Install the compression spring and the 2 pistons to the rear wheel brake cylinder.
d. Install the 2 new cylinder dust boots to the rear wheel brake cylinder.
3. INSTALL FRONT OR UPPER REAR WHEEL BRAKE CYLINDER ASSEMBLY
a. Install the rear wheel brake 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. APPLY HIGH TEMPERATURE GREASE
a. Apply high temperature grease to the shoe attached surface of the backing plate.
5. INSTALL REAR BRAKE PARKING BRAKE SHOE LEVER SUB-ASSEMBLY
a. Using needle-nose pliers, install the parking brake lever with a new C-washer.
6. INSTALL REAR BRAKE SHOE
a. Using needle-nose pliers, connect the No. 3 parking brake cable to the parking brake shoe lever.
b. Using SST, install the rear brake shoe, pin, shoe hold down spring and cup.
SST 09718-00010
7. INSTALL REAR BRAKE SHOE RETURN SPRING
a. Install the rear brake shoe return spring to the rear brake shoe.
8. INSTALL REAR BRAKE AUTOMATIC ADJUST LEVER
a. Install the rear brake automatic adjust lever and the rear brake automatic adjust lever tension spring to the front brake shoe.
9. INSTALL PARKING BRAKE SHOE STRUT SET
a. Apply high temperature grease to the adjusting bolt and assemble the strut set.
b. Install the shoe return spring to the strut set.
c. Install the strut set as shown in the illustration.
10. INSTALL FRONT BRAKE SHOE
a. Connect the tension spring to the front brake shoe and rear brake shoe.
b. Using SST, install the front brake shoe, pin, shoe hold down spring and cup.
SST 09718-00010
11. CONNECT PARKING BRAKE SHOE STRUT SET
a. Using SST, connect the shoe return spring to the front brake shoe and rear brake 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 as shown in the illustration, reinstall them.
b. Measure the brake drum inside diameter and the diameter of the brake shoes. Check that the difference between the diameter is the correct shoe clearance.
Standard shoe clearance: 0.6 mm (0.024 inch)
NOTICE: There should be no oil or grease adhering to the friction surfaces of the shoe lining and the drum.
INSTALLATION
1. INSTALL REAR BRAKE DRUM SUB-ASSEMBLY
a. Aligning the matchmarks, install the rear brake drum.
2. ADJUST REAR DRUM BRAKE SHOE CLEARANCE
a. Temporarily install 2 hub nuts.
b. Remove the hole plug, and turn the adjuster to expand the shoe until the drum locks.
c. Rotate the adjuster by 8 notches.
d. Install the hole plug.
e. Remove the 2 hub nuts.
3. FILL RESERVOIR WITH BRAKE FLUID
4. BLEED AIR FROM FRONT AND REAR BRAKE SYSTEMS
5. CHECK FOR BRAKE FLUID LEAKAGE
6. CHECK FLUID LEVEL IN RESERVOIR
7. INSTALL REAR WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
8. CHECK PARKING BRAKE PEDAL TRAVEL
9. ADJUST PARKING BRAKE PEDAL TRAVEL
10. CHECK AND CLEAR DTC