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BR1

BRAKE SYSTEM

BRAKE SYSTEM

BR2
BRAKE SYSTEM

Precautions

PRECAUTIONS
1. Care must be taken to replace each part properly as it could
affect the performance of the brake system and result in
a driving hazard. Replace the parts with parts of the
same part number or equivalent.
2. It is very important to keep parts and the area clean when
repairing the brake system.

TROUBLESHOOTING
Possible cause

Problem
Low or spongy pedal

Brakes drag

Linings worn

Replace brake shoes or pads

Leak in brake system


Master cylinder faulty
Air in brake system
Wheel cylinder faulty
Piston seals worn or damaged
Rear brake automatic adjuster faulty

Repair leak
Repair or replace master cylinder
Bleed brake system
Repair wheel cylinder
Repair brake calipers
Repair or replace adjuster

Parking brake out of adjustment


Linkage binding
Booster push rod out of adjustment
Return spring faulty
Brake line restricted
Lining cracked or distorted

Adjust parking brake


Repair as necessary
Adjust push rod
Replace spring
Repair as necessary
Replace brake shoes and pads

Wheel cylinder or caliper piston sticking


Automatic adjuster broken

Repair as necessary

Master cylinder faulty


Brakes pull

Remedy

Tires improperly inflated


Oil or grease on linings
Brake shoes distorted, linings worn or
glazed

Brakes grab/chatter

BR16, 22,
30
BR9
BR7
BR22
BR16, 30
BR22
BR8
BR15
BR22

Replace adjuster
Repair or replace master cylinder

BR16, 22,
30
BR16, 22
30
BR22
BR9

Inflate tires to proper pressure


Check for cause/Replace shoes
Replace brake shoes

BR22
BR22

Replace drum or disc


Drum or disc out of round
Return spring faulty wheel cylinder faulty
Piston frozen in caliper
Disc brake pads sticking

Page

Replace spring
Repair wheel cylinder
Repair caliper
Replace pads

BR16, 22,
30
BR22
BR22
BR16, 30
BR16, 30

Oil or grease on linings


Drum or disc scored or out of round

Check for cause/Replace shoes


Replace drum or disc

Brake shoes distorted, linings worn or


glazed
Wheel cylinder faulty
Disc brake pads sticking
Brake booster faulty

Replace brake shoes

BR22
BR16, 22,
30
BR22

Repair wheel cylinder


Replace pads
Repair booster

BR22
BR16, 30
BR14

BR3
BRAKE SYSTEM

Troubleshooting

TROUBLESHOOTING (Contd)
Problem
Hard pedal but
brakes inefficient

Snapping or clicking
noise when brakes are
applied

Scraping or grinding
noise when brakes are
applied

Possible cause

Remedy

Page

Oil or grease on linings

Check for cause/Replace shoes

Brake shoes distorted, linings worn or


glazed, drums worn
Disc brake pads worn
Piston frozen in caliper
Brake booster faulty
Brake line restricted
Vacuum system leaking

Replace brake shoes


Replace pads
Repair caliper
Repair booster
Repair as necessary
Repair or replace

BR16, 30
BR16, 30
BR14

Drum brakesbrake shoes binding at


backing plate ledges
Drum brakesbacking plate ledges worn
Drum brakesloose or missing hold down
spring
Drum brakesloose set bolt at backing
plate
Disc brakesrust on front edge of inboard
pad
Disc brakesloose or missing pad support
plate
Disc brakesloose installation bolt
Disc brakeswear on slide bushing
Pad wear and pad wear indicator making
contact with the rotor

Lubricate

BR22

Replace and lubricate ledges


Replace or hook in

BR22
BR22

Tighten

BR22

Inspect, lubricate/Replace if
necessary
Replace or insert

BR16, 30

Tighten
Replace
Replace

BR16, 30
BR16,30
BR16, 30

Worn brake linings

Replace/Refinish drums or rotors if


heavily scored
Replace as required

BR16, 22,
30
BR16, 22,
30

Caliper to wheel or rotor interference


Dust cover to rotor or drum interference
Other brake system components:
Warped or bent brake backing plate or
splash shield, cracked drums or rotors
Tires rubbing against chassis and body
Pad wear and pad wear indicator making
contact with the rotor

BR16, 22,
30
BR22

BR16, 30

Correct or replace
Inspect and repair

BR16, 30

Inspect and repair


Replace

BR16, 30

BR4
BRAKE SYSTEM

Troubleshooting

TROUBLESHOOTING (Contd)
Problem

Possible cause

Squealing, groaning or
chattering noise when brakes
are applied
NOTE: Brake friction
materials inherently generate
noise and heat in order to
dissipate energy.
As a result, occasional
squeal is normal and is
aggravated by severe
environmental conditions
such as cold, heat, wetness,
snow, salt, mud, etc.
This occasional
squeal is not a functional
problem and does not
indicate any loss of brake
effectiveness

Brake drums and linings, rotors and pads


worn or scored
Disc brakesmissing or damaged brake pad
antisqueal shim
Disc brakesburred or rusted calipers
Dirty, greased, contaminated or glazed
linings
Improper lining parts

Squealing noise when


brakes are not applied

Bent or warped backing plate causing


interference with drum
Improper machining of drum causing
interference with backing plate or shoe
Maladjustment of brake pedal or booster
push rod
Poor return of brake booster or master
cylinder or wheel cylinder
Disc brakesrusted, stuck
Other brake system components:
Loose or extra parts in brakes
Rear drum adjustment too tight causing
lining to glaze
worn, damaged or insufficiently lubricated
wheel bearings
Drum brakesweak, damaged or
incorrect shoe retracting springs
Drum brakesgrooved backing plate
ledges
Improper positioning of pads in caliper
Outside diameter of rotor rubbing caliper
housing
Housing installation of disc brake pad
support plate

Maladjustment of brake pedal or booster


push rod
Drum brakesweak damaged or incorrect
shoe holddown springs, loose or damaged
shoe holddown pins and springs and
grooved backing plate ledges

Remedy

Page

Inspect, repair or replace

BR16,30

Replace
Clean or deburr
Clean or replace

BR16, 30

Inspect and adjust

BR16,30
BR16, 22,
30
BR16, 22,
30
BR6, 15

Inspect, repair or replace

BR22

Repair or replace

BR22

Replace drum

BR22

Inspect and adjust

BR6, 15

Inspect, repair or replace


Inspect/Lubricate if necessary
Inspect, repair, replace as
required

BR9, 14,
16,22
BR16, 30
BR16, 22
30

Inspect, repair or replace

SA8, 23,
31
BR22

Inspect and repair


Inspect, correct or replace

BR22
BR16, 30
BR16, 30

Correct

BR16, 30

Check for correct parts/Replace

BR5
BRAKE SYSTEM

Troubleshooting

TROUBLESHOOTING (Contd)
Problem
Groaning, clicking or
ratting noise when
brakes are not
applied

Possible cause
Stones or foreign material trapped inside
wheel covers
Loose wheel nuts
Disc brakesfailure of shim
Disc brakeswear on slide bushing
Disc brakesloose installation bolt
Maladjustment of brake pedal or booster
push rod
Disc brakespoor return of piston
Drum brakesloose or extra parts
Worn, damaged or dry wheel bearings

Remedy

Page

Remove stones, etc.


Tighten to correct torque/Replace if
stud holes are elongated
Inspect/Replace if necessary
Inspect/Replace if necessary
Inspect/Tighten if necessary
Inspect and adjust
Inspect, repair or replace
Inspect, remove or repair
Inspect, lubricate or replace

BR16, 30
BR16, 30
BR16, 30
BR6,15
BR16,30
BR22
SA8, 34,
42

BR6
BRAKE SYSTEM

Checks and Adjustments

CHECKS AND ADJUSTMENTS


CHECK AND ADJUSTMENT OF BRAKE
PEDAL
1. CHECK THAT PEDAL HEIGHT IS CORRECT, AS SHOWN
Pedal height from asphalt sheet:
139 149 mm (5.47 5.87 in.)
2. IF NECESSARY, ADJUST PEDAL HEIGHT
(a) Sufficiently loosen the stop light switch.
(b) Adjust the pedal height by turning the pedal push rod.
(c) Return the stop light switch until it lightly contacts the pedal
stopper.
(d) After adjusting the pedal height, check and adjust the pedal
freeplay.

3. CHECK THAT PEDAL FREEPLAY IS CORRECT, AS


SHOWN
(a) Stop the engine and depress the brake pedal several
times until there is no more vacuum left in the booster.
(b) Push in the pedal until the beginning of resistance is felt.
Measure the distance, as shown.
Pedal freeplay: 3 6 mm (0.12 0.24 in.)
HINT: The pedal freeplay is the amount of the stroke until
the booster air valve is moved by the pedal push rod.
4. IF NECESSARY, ADJUST PEDAL FREEPLAY
(a) If incorrect, adjust the pedal freeplay by turning the pedal push rod and tighten the clevis lock nut.
Torque: 260 kgcm (19 ftIb, 25 Nm)

(b) Start the engine and confirm that pedal freeplay exists.
(c) After adjusting the pedal freeplay, check the pedal
height.

5. CHECK THAT PEDAL RESERVE DISTANCE IS CORRECT,


AS SHOWN
Release the parking brake lever.
With engine running, depress the pedal and measure the
pedal reserve distance, as shown.
Pedal reserve distance from asphalt sheet at 50 kg (110.2
Ib, 490 N):
Rear drum brake type More than 55 mm (2.17 in.)
Rear disc brake type More than 60 mm (2.36 in.)
4WD More than 65 mm (256 in.)
If incorrect,troubleshoot the brake system.

BR7
BRAKE SYSTEM

Checks and Adjustments

OPERATIONAL TEST OF BRAKE


BOOSTER
HINT: If available, use a brake booster tester to check the
booster operating condition.
1. OPERATING CHECK
(a) Depress the brake pedal several times with the engine off,
and check that there is no change in the pedal reserve distance.
(b) Depress the brake pedal and start engine. If the pedal goes
down slightly, operation is normal.
2. AIR TIGHTNESS
(a) Start the engine and stop it after one or two minutes.
Depress the brake pedal several times slowly. If the pedal
goes down deepest the first time, but gradually rises after
the second or third time, the booster is air tight.
(b) Depress the brake pedal while the engine is running, and
stop the engine with the pedal depressed. If there is no
change in pedal reserve travel after holding the pedal for
thirty seconds, the booster is air tight.

BLEEDING OF BRAKE SYSTEM


HINT: If any work is done on the brake system or if air is suspected in the brake lines, bleed the system of air.
NOTICE: Do not let brake fluid remain on a painted surface. Wash
it off immediately.

1. FILL BRAKE RESERVOIR WITH BRAKE FLUID


Check the reservoir after bleeding each wheel. Add fluid, if
necessary.

2. BLEED MASTER CYLINDER


HINT: If the master cylinder was disassembled or if the
reservoir tank becomes empty, bleed the air from the
master cylinder.
(a) Disconnect the brake tubes from the master cylinder.
Use a container to catch the brake fluid.
(b) Slowly depress the brake pedal and hold it.

(c) Block off the outlet plug with your finger, and release the brake pedal.
(d) Repeat (b) and (c) three or four times.
(e) Connect the brake tubes to the master cylinder.

BR8
BRAKE SYSTEM

Checks and Adjustments

3. CONNECT VINYL TUBE TO WHEEL CYLINDER BLEEDER


PLUG
Insert other end of the tube in a halffull container of brake
fluid.
HINT: Begin air bleeding from the wheel cylinder with the longest hydraulic line.
4. BLEED BRAKE LINE
(a) Slowly pump the brake pedal several times.
(b) While an assistant depresses the pedal, loosen the bleeder
plug until fluid starts to run out. Then close the bleeder plug.
(c) Repeat this procedure until there are no more air bubbles in
the fluid.
Bleeder plug tightening torque: 85 kgcm
(74 in.Ib, 8.3 N m)
5. REPEAT PROCEDURE FOR EACH WHEEL

CHECK AND ADJUSTMENT OF PARKING


BRAKE
1. CHECK THAT PARKING BRAKE LEVER TRAVEL IS
CORRECT
Pull the parking brake lever all the way up, and count the number
of clicks.
Parking brake lever travel at 20 kg (44.1 Ib, 196 N )
Rear drum brake type 4 7 clicks
Rear disc brake type 5 8 clicks
2. IF NECESSARY, ADJUST PARKING BRAKE
HINT: Before adjusting the parking brake, make sure that the
rear brake shoe clearance has been adjusted.
For shoe clearance adjustment, see steps 8 and 9 on page
BR29 and step 9 on page BR39.
(a) Remove the console box.
(b) Loosen the lock nut and turn the adjusting nut until the travel is
correct.
(c) Tighten the lock nut and install the console box.
Torque: 55 kgcm (48 in.Ib, 5.4 Nm)

BR9
BRAKE SYSTEM

Master Cylinder

MASTER CYLINDER
REMOVAL OF MASTER CYLINDER

1. DISCONNECT LEVEL WARNING SWITCH


CONNECTOR
2. DRAW OUT FLUID WITH SYRINGE
NOTICE: Do not let brake fluid remain on a painted surface. Wash it
off immediately.

3. DISCONNECT BRAKE TUBES


Using SST, disconnect the brake tubes from the master cylinder.
SST 0975136011
4. REMOVE MASTER CYLINDER
Remove the mounting nuts and pull out the master cylinder and
gasket.

BR10
BRAKE SYSTEM

Master Cylinder

COMPONENTS

DISASSEMBLY OF MASTER
CYLINDER
1. REMOVE RESERVOIR
(a) Remove the set screw and pull out the reservoir.
(b) Remove the cap and strainer from the reservoir.
2. REMOVE TWO GROMMETS
3. PLACE CYLINDER IN VISE

4. REMOVE PISTON STOPPER BOLT


Using a screwdriver, push the pistons in all the way and
remove the piston stopper bolt and gasket.
HINT: Tape the screwdriver tip before use.

BR11
BRAKE SYSTEM

Master Cylinder

5. REMOVE TWO PISTONS AND SPRINGS


(a) Push in the piston with a screwdriver and remove the
snap ring with snap ring pliers.
(b) Remove the No. 1 piston and spring by hand, pulling
straight out, not at an angle.

(c) Place a rag and two wooden blocks on the work


table and lightly tap the cylinder flange against
the block edges until the No.2 piston drops out
of cylinder.
HINT: Make sure the distance (A) from the rag to
the top of the blocks is at least 100 mm (3.94 in.).

INSPECTION OF MASTER CYLINDER


COMPONENTS
HINT: Clean the disassembled parts with compressed air.
1. INSPECT MASTER CYLINDER BORE FOR RUST OR
SCORING
2. INSPECT CYLINDER FOR WEAR OR DAMAGE
If necessary, clean or replace the cylinder.

ASSEMBLY OF MASTER CYLINDER


(See page BR10)
1. APPLY LITHIUM SOAP BASE GLYCOL GREASE TO
RUBBER PARTS INDICATED BY ARROWS

2. INSTALL TWO SPRINGS AND PISTONS


NOTICE: Be careful not to damage the rubber lips on the
pistons.

(a) Insert the two springs and pistons straight in, not at an
angle.
NOTICE: If inserted at an angle, there is a possibility of
damaging the cylinder bore.

(b) Push in the piston with a screwdriver and install the


snap ring with snap ring pliers.
HINT: Tape the screwdriver tip before use.
NOTICE: Be careful not to scratch the cylinder bore.

BR12
BRAKE SYSTEM

Master Cylinder

3. INSTALL PISTON STOPPER BOLT


Using a screwdriver, push the piston in all the way and
install the piston stopper bolt over the gasket. Torque
the bolt.
Torque: 100 kgcm (7 ftIb, 10 Nm)

4. INSTALL TWO GROMMETS

5. INSTALL RESERVOIR
(a) Install the cap and strainer to the reservoir.
(b) Push the reservoir onto the cylinder.
(c) Install the set screw while pushing on the reservoir.
Torque: 17.5 kgcm (15.2 in.Ib, 1.7 Nm)

NOTICE: Because the master cylinder and reservoir


tank union is a grommet type, the set screw is designed to not separate the reservoir from cylinder
and will not tighten down the reservoir. Therefore,
there is a clearance at point A. Do not insert washers
or an equivalent when tightening.

BR13
BRAKE SYSTEM

Master Cylinder

INSTALLATION OF MASTER
CYLINDER
(See page BR9)
1. CLEAN OUT GROOVE ON LOWER INSTALLATION
SURFACE OF MASTER CYLINDER
2. CONFIRM THAT UP MARK ON MASTER CYLINDER
BOOT IS IN CORRECT POSITION

3. ADJUST LENGTH OF BRAKE BOOSTER PUSH ROD


BEFORE INSTALLING MASTER CYLINDER
(See page BR15)

4. INSTALL MASTER CYLINDER


Install the master cylinder and gasket on the brake
booster with nuts and install 3way union.
Torque: 130 kgcm (9 ftIb, 13 Nm)

5. CONNECT BRAKE TUBES


Using SST, connect the brake tubes to the master cylinder.
Torque the union nuts.
SST 0975136011
Torque: 155 kgcm (11 ftIb, 15 Nm )

6. CONNECT LEVEL WARNING SWITCH CONNECTOR


7. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND
BLEED BRAKE SYSTEM
(See page BR7)
8. CHECK FOR FLUID LEAKAGE
9. CHECK AND ADJUST BRAKE PEDAL
(See page BR6)

BR14
BRAKE SYSTEM

Brake Booster

BRAKE BOOSTER
REMOVAL OF BRAKE BOOSTER

1. REMOVE MASTER CYLINDER


(See page BR9)
2. DISCONNECT VACUUM HOSE FROM BRAKE
BOOSTER
3. REMOVE PEDAL RETURN SPRING
4. REMOVE CLIP AND CLEVIS PIN

5. REMOVE BRAKE BOOSTER, GASKET AND CLEVIS

BR15
BRAKE SYSTEM

Brake Booster

INSTALLATION OF BRAKE BOOSTER


(See page BR14)
1. ADJUST LENGTH OF BOOSTER PUSH ROD
(a) Install the gasket on the master cylinder.
(b) Set the SST on the gasket, and lower the pin until its
tip slightly touches the piston.
SST 0973700010

(c) Turn the SST upside down, and set it on the booster.
SST 0973700010
(d) Measure the clearance between the booster push rod and pin
head (SST).
Clearance: 0 mm (0 in.)
(e) Adjust the booster push rod length until the push rod lightly
touches the pin head.

2. INSTALL BRAKE BOOSTER, GASKET AND CLEVIS


(a) Install the booster and gasket.
(b) Install the clevis.
(c) Install and torque the booster mounting nuts.
Torque: 130 kgcm (9 ftIb, 13 Nm)

3. CONNECT CLEVIS TO BRAKE PEDAL


Insert the clevis pin into the clevis through the brake
pedal and install the clip to the clevis pin.
4. INSTALL PEDAL RETURN SPRING
5. INSTALL MASTER CYLINDER AND 3WAY UNION
(See page BR13)
6. CONNECT HOSE TO BRAKE BOOSTER
7. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND
BLEED BRAKE SYSTEM (See page BR7)
8. CHECK FLUID LEAKAGE
9. CHECK AND ADJUST BRAKE PEDAL
(See page BR6)
10. PERFORM OPERATIONAL CHECK
(See page BR7)

BR16
BRAKE SYSTEM

Front Brake

FRONT BRAKE
COMPONENTS

REPLACEMENT OF BRAKE PADS


HINT: If a squealing noise occurs from the brakes while
driving, check the pad wear indicator plate. If. the pad
wear indicator plate contacts the rotor disc, the brake
pads should be replaced.
1. REMOVE FRONT WHEEL
Remove the wheel and temporarily fasten the rotor disc
with the wheel nuts.

2. INSPECT PAD LINING THICKNESS


Check the pad thickness through the cylinder inspection hole and replace pads if not within specification.
Minimum thickness: 1.0 mm (0.039 in.)

BR17
BRAKE SYSTEM

Front Brake

3. REMOVE CYLINDER FROM TORQUE PLATE


(a) Remove the two installation bolts from the torque
plate.
(b) Remove the brake cylinder and suspend it so the
hose is not stretched.
HINT: Do not disconnect the brake hose.

4. REMOVE FOLLOWING PARTS

Two antisqueal springs

Two brake pads

Three antisqueal shims

A pad wear indicator plate

Four pad support plates


5. CHECK ROTOR DISC THICKNESS
(See step 2 on page BR20)
6. CHECK ROTOR DISC RUNOUT
(See step 3 on page BR20)
7. INSTALL NEW PAD SUPPORT PLATES
Install the four pad support plates to the torque plate.

8. INSTALL NEW PADS


(a) Install a pad wear indicator plate to the inside pad.
HINT: Be sure the arrow on the pad wear indicator
plate is pointing in the direction of the rotor disc rotation.
(b) Install the antisqueal shims to the pads.
HINT: Apply disc brake grease to both side of the inner
antisqueal shim of the outside pad.

(c) Install the pads onto each support plate.


NOTICE: Do not allow oil or grease to get on the rubbing face.

(d) Install the antisqueal springs in position.

BR18
BRAKE SYSTEM

Front Brake

9. INSTALL CYLINDER
(a) Draw out a small amount of brake fluid from the reservoir.
(b) Press in the piston with a hammer handle or an equivalent.
HINT: Always change the pad on one wheel at a time as
there is possibility of the opposite piston flying out.
(c) Insert the brake cylinder carefully so the dust boot is not
wedged.

(d) Install and torque the two installation bolts.


Torque: 255 kgcm (18 ftIb, 25 Nm)

10. INSTALL FRONT WHEEL


11. FILL BRAKE FLUID

REMOVAL OF CYLINDER
(See page BR16)
1. DISCONNECT BRAKE HOSE
Remove the union bolt and disconnect the flexible
hose.
Use a container to catch the brake fluid.

2. REMOVE BRAKE CYLINDER FROM TORQUE PLATE


Remove the two installation bolts and cylinder.

3. REMOVE PADS
(See step 4 on page BR17)

BR19
BRAKE SYSTEM

Front Brake

DISASSEMBLY OF CYLINDER
(See page BR16)
1. REMOVE FOLLOWING PARTS

Two cylinder sliding bushings


Four dust boots

2. REMOVE CYLINDER BOOT SET RING AND BOOT


Using a screwdriver, remove the cylinder boot set ring
and remove the cylinder boot.

3. REMOVE PISTON FROM CYLINDER


(a) Put a piece of cloth or an equivalent between the piston
and cylinder.
(b) Use compressed air to remove the piston from the cylinder.
CAUTION: Do not place your fingers in front of the piston
when using compressed air.

4. REMOVE PISTON SEAL FROM BRAKE CYLINDER


Using a screwdriver, remove the piston seal.

BR20
BRAKE SYSTEM

Front Brake

INSPECTION AND REPAIR OF FRONT BRAKE


COMPONENTS
1. MEASURE PAD LINING THICKNESS
Standard thickness: 10.0 mm (0.394 in.)
Minimum thickness: 1.0 mm (0.039 in.)
Replace the pad if the thickness is less than the minimum or if it
shows sign of uneven wear.

2. MEASURE ROTOR DISC THICKNESS


Standard thickness:
4AGE Engine 22.0 mm (0.866 in.)
4AFE Engine 18.0 mm (0.709 in.)
Minimum thickness:
4AGE Engine 21.0 mm (0.827 in.)
4AFE Engine 17.0 mm (0.669 in.)
If the disc is scored or worn, or if thickness is less
than minimum, repair or replace the disc.
3. MEASURE ROTOR DISC RUNOUT
HINT: Before measuring the runout, confirm that the
front hub bearing play is within specification.
Measure the rotor disc runout at 10 mm (0.39 in.) from
the outer edge of the rotor disc.
Maximum disc runout: 0.09 mm (0.0035 in.)
If the runout is greater than the maximum, inspect and
adjust it following the procedure below:
Then replace the disc if necessary.
(a) Remove the torque plate from the knuckle.
(b) Remove the hub nuts of the temporarily installed disc
and pull off the rotor disc.
(c) Check that the hub axial play is within specification,
and replace the bearing if not within specification.
(d) Install the rotor disc and measure the disc runout,
then shift the rotor disc one fourth of a turn and
measure the disc runout. Similarly measure the
runout at each position, and select the position
where the runout is minimum.

(e) In this position, if the runout is within specification, install the torque plate and torque the
mounting bolts.
Torque: 900 kgcm (65 ftIb, 88 Nm)

(f) If not within specification, replace the rotor disc,


and repeat (d) and (e).

BR21
BRAKE SYSTEM

Front Brake

ASSEMBLY OF CYLINDER
(See page BR16)
1. APPLY LITHIUM SOAP BASE GLYCOL GREASE TO
PARTS INDICATED BY ARROWS
2. INSTALL PISTON SEAL AND PISTON IN CYLINDER
3. INSTALL CYLINDER BOOT AND SET RING IN
CYLINDER

4. INSTALL DUST BOOTS AND CYLINDER SLIDING


BUSHING
(a) Install the four dust boots to the brake cylinder.
(b) Insure that the boots are secured firmly to each brake cylinder groove.
(c) Install the sliding bushings into the boots.
(d) Insure that the boots are secured firmly to each, bushing
groove.

INSTALLATION OF CYLINDER
(See page BR16)
1. INSTALL PADS
(See step 7 and 8 on page BR17)
2. INSTALL CYLINDER
(See step 9 on page BR18)

3. CONNECT FLEXIBLE HOSE


Set the flexible hose and new gaskets in position and
install the union bolt.
Torque: 310 kgcm (22 ftIb, 30 Nm)

4. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND


BLEED BRAKE SYSTEM (See page BR7)
5. CHECK FOR FLUID LEAKAGE

BR22
BRAKE SYSTEM

Rear Brake

REAR BRAKE
Drum Brake
COMPONENTS

BR23
BRAKE SYSTEM

Rear Brake

REMOVAL OF REAR BRAKE


1. INSPECT SHOE LINING THICKNESS
Remove the inspection hole plug, and check the shoe
lining thickness through the hole.
If less than minimum, replace the shoes.
Minimum thickness: 1.0 mm (0.039 in.)
2. REMOVE REAR WHEEL

3. REMOVE BRAKE DRUM


If the brake drum cannot be removed easily, perform
the following steps.
(a) Insert a screwdriver through the hole in the backing
plate, and hold the automatic adjusting lever away
from the adjuster.
(b) Using another screwdriver, reduce the brake shoe adjustment by turning the adjusting bolt.

4. REMOVE FRONT SHOE


(a) Using SST, remove the return spring.
SST 0970330010
Using SST, remove the shoe holddown spring, two
cups and pin from the front shoe.
SST 0971800010
(c) Disconnect the anchor spring from the front shoe and
remove the front shoe.
(d) Remove the anchor spring from the rear shoe.
5. REMOVE ADJUSTER AND REAR SHOE
(a) Using SST, remove the shoe holddown spring, two
cups and pin from the rear shoe.
SST 09718 10
(b) Using pliers, remove the adjusting lever spring.

(c) Remove the adjuster together with the return spring.


(d) Using pliers, disconnect the parking brake cable from
the lever and remove the rear shoe.

BR24
BRAKE SYSTEM

Rear Brake

6. DISCONNECT BRAKE TUBE FROM WHEEL


CYLINDER
Using SST, disconnect the brake tube. Use a container
to catch the brake fluid.
SST 0975136011

7. REMOVE WHEEL CYLINDER


Remove the two bolts and wheel cylinder.

8. REMOVE FOLLOWING PARTS FROM WHEEL


CYLINDER
(a) Two boots
(b) Two pistons
(c) Two piston cups
(d) Spring

INSPECTION AND REPAIR OF REAR BRAKE


COMPONENTS
1. INSPECT DISASSEMBLED PARTS
Inspect the disassembled parts for wear, rust or damage.

2. INSPECT BRAKE SHOE LINING THICKNESS


Standard thickness: 4.0 mm (0.157 in.)
Minimum thickness: 1.0 mm (0.039 in.)
If the shoe lining is less than minimum or shows signs
of uneven wear, replace the brake shoes.
HINT: If any of the brake shoes have to be replaced,
replace all of the rear brake shoes in order to maintain
even braking.

BR25
BRAKE SYSTEM

Rear Brake

3. INSPECT BRAKE DRUM INSIDE DIAMETER


Standard inside diameter: 200.0 mm (7.874 in.)
Maximum inside diameter: 201.0 mm (7.913 in.)
If the drum is scored or worn, the brake drum may be
lathed to the maximum inside diameter.

4. INSPECT BRAKE LINING AND DRUM FOR PROPER


CONTACT
If the contact between the brake lining and drum is improper, repair the lining with a brake shoe grinder, or
replace the brake shoe assembly.

5. MEASURE CLEARANCE BETWEEN BRAKE SHOE


AND LEVER
Using a feeler gauge, measure the clearance.
Standard clearance: Less than 0.35 mm (0.0138 in.)
If the clearance is not within specification, replace the
shim with one of the correct size.
Shim thickness

6. IF NECESSARY, REPLACE SHIM


(a) Remove the parking brake shoe lever, and install the
correct size shim.

(b) Install the parking brake shoe lever with a new


Cwasher.
(c) Remeasure the clearance.

BR26
BRAKE SYSTEM

Rear Brake

INSTALLATION OF REAR BRAKE


(See page BR22)
HINT: Assemble the parts in the correct direction as shown.

1. APPLY LITHIUM SOAP BASE GLYCOL GREASE TO


FOLLOWING PARTS
(a) Two piston cups
(b) Two pistons

BR27
BRAKE SYSTEM

Rear Brake

2. ASSEMBLE WHEEL CYLINDER


(a) Install two piston cups to the pistons.
(b) Install the spring and two pistons into the wheel cylinder. Check that the flanges of the piston are pointed
inward.
(c) Install two boots.

3. INSTALL WHEEL CYLINDER


Install the wheel cylinder on the backing plate with the
two bolts.
Torque: 100 kgcm (7 ftIb, 10 Nm)

4. CONNECT BRAKE TUBE TO WHEEL CYLINDER


Using SST, connect the brake tube.
SST 0975136011
Torque: 155 kgcm (11 ftIb, 15 Nm)

5. APPLY HIGH TEMPERATURE GREASE TO


FOLLOWING PARTS
(a) Backing plate and brake shoe contact points
(b) Anchor plate and brake shoe contact points

(c) Adjusting bolt


(d)Adjuster and brake shoe contact
points

BR28
BRAKE SYSTEM

Rear Brake

6. INSTALL ADJUSTER AND REAR SHOE


(a) Using pliers, connect the parking brake cable to the lever.

(b) Set the adjuster and return spring.

(c) Install the adjusting lever spring.


(d) Set the rear shoe in place with the end of the shoe inserted in the wheel cylinder and the other end in the
anchor plate.
NOTICE: Do not allow oil or grease to get on the rubbing
face.

(e) Using SST, install the shoe holddown spring, two


cups and pin. SST 0971800010
7. INSTALL FRONT SHOE
(a) Install the anchor spring between the front and rear
shoes.
(b) Set the front shoe in place with the end of the shoe inserted in the wheel cylinder and the adjuster in place.
NOTICE: Do not allow oil or grease to get on the rubbing
face.

(c) Using SST, install the shoe holddown spring, two cups
and pin.
SST 0971800010
(d) Using SST, connect the return spring.
SST 0970330010

BR29
BRAKE SYSTEM

Rear Brake

8. CHECK OPERATION OF AUTOMATIC ADJUSTING


MECHANISM
(a) Move the parking brake lever of the rear shoe back
and forth, as shown. Check that the adjusting bolt
turns.
If the adjusting bolt does not turn, check for incorrect
installation of the rear brakes.

(b) Adjust the adjuster length to the shortest possible


amount.
(c) Install the drum.
(d) Pull the parking brake lever all the way up until a clicking
sound can no longer be heard.

9. CHECK CLEARANCE BETWEEN BRAKE SHOES AND


DRUM
(a) Remove the drum.
(b) Measure the brake drum inside diameter and diameter
of the brake shoes. Check that the difference between the diameters is the correct shoe clearance.
Shoe clearance: 0.6 mm (0.024 in.)
If incorrect, check the parking brake system.

10. INSTALL BRAKE DRUM AND REAR WHEEL


11. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND
BLEED BRAKE SYSTEM
12. CHECK FOR FLUID LEAKAGE

BR30
BRAKE SYSTEM

Rear Brake

Disc Brake
COMPONENTS

REPLACEMENT OF BRAKE PADS


HINT: If a squealing noise occurs from the rear brakes
while driving, check the pad wear indicator plate. If
there are traces of the indicator plate contacting the
rotor disc, the brake pad should be replaced.
1. REMOVE REAR WHEEL
Remove the wheel and temporarily fasten the rotor
disc with the hub nuts.

2. INSPECT PAD LINING THICKNESS


Check the pad thickness through the cylinder inspection hole and replace pads if not within specification.
Minimum thickness: 1.0 mm (0.039 in.)

BR31
BRAKE SYSTEM

Rear Brake

3. REMOVE CYLINDER FROM TORQUE PLATE


(a) Remove the installation bolt from the torque plate.
(b) Remove the brake cylinder and suspend it so the hose
is not stretched.
HINT: Do not remove the cylinder from the main pin,
and do not disconnect the brake hose.

4. REMOVE FOLLOWING PARTS:

Two
Two
Two
Two

brake pads
antisqueal shims
antirattle springs
pad guide plates

5. INSTALL PAD GUIDE PLATES AND ANTIRATTLE


SPRINGS

6. INSTALL NEW PADS AND ANTISQUEAL SHIMS


(a) Install the antisqueal shims to the pads.
(b) Raise the cylinder, and install the pads to the torque
plate.
HINT: Install the pads so the wear indicator is at the top
side.
NOTICE: Do not allow oil or grease to get on the rubbing
face.

7. LOWER CYLINDER
(a) Using SST, slowly turn the piston clockwise while
pushing it into where it locks.
SST 0971914020 (0971900020)

BR32
BRAKE SYSTEM

Rear Brake

(b) Fit the pad protrusion into the piston stopper


groove, and install the cylinder.
HINT: Insert the cylinder carefully so the boot is
not wedged.

8. INSTALL CYLINDER INSTALLATION BOLT


Install and torque the cylinder installation bolt.
Torque: 200 kgcm (14 ftIb, 20 N m )

9. INSTALL REAR WHEEL


10. CHECK THAT FLUID LEVEL IS AT MAX LINE
11. ADJUST PARKING BRAKE AUTOMATIC ADJUSTER
BY DEPRESSING BRAKE PEDAL SEVERAL TIMES

REMOVAL OF CYLINDER
(See page BR26)
1. DISCONNECT BRAKE HOSE FROM CYLINDER
(a) Remove the union bolt and two gaskets, and disconnect the brake hose.
(b) Use a container to catch the brake fluid.
2. DISCONNECT PARKING BRAKE CABLE FROM CYLINDER

3. REMOVE CYLINDER
Remove the installation bolt and cylinder.

DISASSEMBLY OF CYLINDER
(See page BR30)
1. REMOVE SLIDING BUSHING AND BOOT
2. REMOVE MAIN PIN BOOT
3. REMOVE CYLINDER BOOT SET RING AND CYLINDER
BOOT

BR33
BRAKE SYSTEM

Rear Brake

4. REMOVE PISTON FROM CYLINDER


Using SST, turn piston counterclockwise and remove it.
SST 0971914020 (0971900020)
5. REMOVE PISTON SEAL FROM CYLINDER

6. REMOVE SNAP RING FROM CYLINDER


(a) Set SST onto the adjusting bolt, and lightly tighten it
with a 14 mm socket.
SST 0975600010
NOTICE:

To insure safety, always use SST as there is a possibility of the spring flying out, causing injury or damage to the interior surface of the cylinder.

Be careful not to tighten the SST too tightly as this


may damage the spring retainer.

(b) Using snap ring pliers, remove the snap ring from the
cylinder.

7. REMOVE ADJUSTING BOLT


From the cylinder, pull out the spring retainer, spring,
spring plate and stopper together with the adjusting
bolt.
NOTICE:

Be careful not to pry too hard.

Be careful not to damage the Oring.

8. DISASSEMBLE ADJUSTING BOLT


(a) Remove SST.
SST 0975600010
(b) Remove the spring retainer, spring, spring plate and
stopper from the adjusting bolt.
(c) Remove the Oring from the adjusting bolt.
9. REMOVE PARKING BRAKE STRUT
10. REMOVE CABLE SUPPORT BRACKET

BR34
BRAKE SYSTEM

Rear Brake

11. REMOVE TORSION SPRING FROM PARKING BRAKE


CRANK
12. REMOVE PARKING BRAKE CRANK FROM CYLINDER

13. REMOVE PARKING BRAKE CRANK BOOT


Using a screwdriver, lightly tap on the metal portion of
the boot and remove it.
HINT: Do not remove the boot unless replacing it.
14. REMOVE STOPPER PIN

INSPECTION AND REPAIR OF REAR BRAKE


COMPONENTS
1. MEASURE PAD LINING THICKNESS
Standard thickness: 10.0 mm (0.394 in.)
Minimum thickness: 1.0 mm (0.039 in.)
Replace the pad if the thickness is less than the minimum or if it
shows sign of uneven wear.

2. MEASURE ROTOR DISC THICKNESS


Standard thickness: 9.0 mm (0.354 in.)
Minimum thickness: 8.0 mm (0.315 in.)
If the disc is scored or worn, if thickness is less than
minimum, repair or replace the disc.

3. MEASURE ROTOR DISC RUNOUT


Measure the rotor disc runout at 10 mm (0.39 in.) from
the outer edge of the rotor disc.
Maximum disc runout: 0.10 mm (0.0039 in.)
If the runout is greater than the maximum, replace the
disc.

BR35
BRAKE SYSTEM

Rear Brake

4. IF NECESSARY, REPLACE ROTOR DISC


(a) Remove the torque plate from the rear axle carrier.
(b) Remove the hub nuts and rotor disc.
(c) Install a new rotor disc and temporarily fasten the hub nuts.
(d) Install the torque plate to the rear axle carrier.
Torque: 475 kgcm (34 ftIb, 47 N m )

ASSEMBLY OF CYLINDER
(See page BR30)
1. APPLY LITHIUM SOAP BASE GLYCOL GREASE TO
PARTS INDICATED BY ARROWS
HINT: Pack the lithium soap base glycol grease into
areas marked A.

2. INSTALL STOPPER PIN


Tap in the pin to the brake cylinder until the stopper pin
extends 25 mm (0.98 in.).

BR36
BRAKE SYSTEM

Rear Brake

3. INSTALL PARKING BRAKE CRANK BOOT IN CYLINDER


Using a 24 mm socket wrench, tap in the boot to the
cylinder.

4. INSTALL PARKING BRAKE CRANK IN CYLINDER


NOTICE: Securely match the crank boot with the groove
of the crank seal.

5. INSTALL CABLE SUPPORT BRACKET


(a) Press the surface of the support bracket flush against the
cylinder wall and tighten the bolt.
Torque: 475 kgcm (34 ftib, 47 Nm)

(b) Check that the clearance between the parking brake crank
and cable support bracket is 0.6 mm (0.236 in.).

6. INSTALL TORSION SPRING


Install the torsion spring and check that the parking brake
crank subassembly is in touch with the stopper pin.

7. INSTALL PARKING BRAKE STRUT


Before installing the strut, adjust the rollers of the needle roller
bearing so they do not catch on the cylinder hole.
Then install the strut to the cylinder.
8. INSTALL A NEW ORING TO ADJUSTING BOLT

BR37
BRAKE SYSTEM

Rear Brake

9. ASSEMBLE ADJUSTING BOLT


(a) Assemble the stopper, plate, spring and spring retainer to the adjusting bolt, and using SST, fully tighten
them down by hand.
SST 0975600010
NOTICE:

Position the inscribed surface of the stopper upward.

Align the notches of the spring retainer with the


notches of the stopper.

(b) Install the adjusting bolt subassembly into the cylinder.

10. INSTALL SNAP RING


(a) Using snap ring pliers, install the snap ring.
HINT: Face the snap ring opening toward the bleeder side.
(b) Remove SST.
SST 0975600010
(c) Firmly pull up the adjusting bolt by hand and insure that it
does not move.

11. PERFORM OPERATIONAL CHECK


After performing steps 1 to 10, move the parking brake
crank by hand and insure that the adjusting bolt
moves smoothly.
12. INSTALL PISTON SEAL IN CYLINDER

13. ASSEMBLE PISTON IN CYLINDER


(a) Using SST, slowly screw in the piston clockwise until
it will not descend any further.
SST 0971914020 (0971900020)

BR38
BRAKE SYSTEM

Rear Brake

(b) Align the center of the piston stopper groove with the
positioning protrusion of the cylinder.
14. INSTALL CYLINDER BOOT IN CYLINDER
15. INSTALL SET RING IN CYLINDER
16. INSTALL MAIN PIN BOOT

17. INSTALL DUST BOOT AND SLIDING BUSHING


(a) Install the dust boot.
HINT: Be careful that the seal does not fold under.
(b) Install the bushing into the boot.

INSTALLATION OF CYLINDER
(See page BR30)
1. INSTALL ANTIRATTLE SPRINGS AND PAD GUIDE
PLATES
(See step 5 on page BR31)
2. INSTALL PADS AND ANTISQUEAL SHIMS
(See step 6 on page BR31)

3. INSTALL CYLINDER ONTO MAIN PIN


Install the cylinder onto the main pin.
HINT: Make sure that the boot end is installed into the
groove of the main pin.
4. CONNECT PARKING BRAKE CABLE

5. INSTALL CYLINDER
(a) Fit the pad protrusion into the piston stopper groove,
and install the cylinder.
HINT: Insert the cylinder carefully so the boot is not
wedged.

BR39
BRAKE SYSTEM

Rear Brake

(b) Install the cylinder installation bolt and torque the


bolt.
Torque: 200 kgcm (14 ftIb, 20 N m )

(c) Install the parking brake cable clip.

6. CONNECT BRAKE HOSE


Install the brake hose in position, and tighten the union
bolt through new gaskets.
Torque: 310 kgcm (22 ftIb, 30 Nm)

7. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND


BLEED BRAKE SYSTEM (See page BR7)
8. CHECK FOR FLUID LEAKAGE

9. ADJUST PARKING BRAKE LEVER TRAVEL


(a) Pull up the parking brake lever for a few times.
(b) Release the parking brake lever.
(c) Depress the brake pedal several times and adjust the
rear brake automatically.
(d) Check that the parking brake crank touches the stopper pin.

(e) Pull the parking brake lever all the way up, and count the
number of clicks.
Parking brake lever travel at 20 kg (44.1 Ib, 196N):
5 8 clicks
(f) If necessary, adjust parking brake lever travel.
(See page BR8)

BR40
BRAKE SYSTEM

Proportioning Valve

PROPORTIONING VALVE (P VALVE)


CHECK OF FLUID PRESSURE
1. CONNECT FLUID PRESSURE GAUGE TO P VALVE

2. BLEED AIR FROM FLUID PRESSURE GAUGE


3. RAISE MASTER CYLINDER PRESSURE AND CHECK REAR
WHEEL CYLINDER PRESSURE
Specifications
Master cylinder pressure

Rear wheel cylinder pressure

4AG E

4AFE

If the rear wheel cylinder pressure is incorrect, replace


the P valve assembly.
4. BLEED BRAKE SYSTEM
5. CHECK FLUID LEAKAGE