Rear

REAR BRAKE
OVERHAUL

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

1. REMOVE REAR WHEEL
2. DRAIN BRAKE FLUID
a. Draw out fluid with syringe.

NOTICE: Wash brake fluid off immediately if it adheres to any painted surfaces.





3. REMOVE REAR DISC BRAKE W/HOLE PIN
a. Remove the clip.
b. Remove the rear disc brake w/ hole pin while pushing on the rear disc brake anti-rattle spring.
4. REMOVE REAR DISC BRAKE ANTI-RATTLE SPRING

NOTICE: The anti-rattle spring and clip can be used again if they have sufficient rebound, no deformation, cracks or wear, and have had all rust, dirt and foreign particles cleaned off.

5. REMOVE DISC BRAKE PAD KIT REAR (PAD ONLY)
a. Remove the 2 pads and the 2 anti-squeal shims from each pad.





b. Right wheel: Remove the clamp, clip and bleeder plug cap, and disconnect the pad wear indicator assembly from the inner pad.





6. INSPECT PAD LINING THICKNESS
a. Using a ruler, measure the pad lining thickness.
Standard thickness: 11.0 mm (0.433 inch)
Minimum thickness: 1.0 mm (0.039 inch)
If the pad lining thickness is less than the minimum, replace the pad.





7. DISCONNECT REAR LH FLEXIBLE HOSE
a. Remove the union bolt and gasket from the disc brake cylinder assembly rear, then disconnect the flexible hose from the disc brake cylinder assembly rear.





8. REMOVE DISC BRAKE CYLINDER ASSEMBLY REAR LH
a. Remove the 2 bolts and the disc brake cylinder assembly rear from the knuckle.





9. REMOVE CYLINDER BOOT
a. Using a screwdriver, remove the cylinder boot from the disc brake cylinder assembly rear.
10. REMOVE REAR DISC BRAKE PISTON





a. Prepare a wooden plate to hold the pistons.





b. Place the plate between the pistons and insert a pad into one side.
c. Use compressed air to remove the pistons alternately from the disc brake cylinder assembly rear.

CAUTION: Do not place your fingers in front of the pistons when using compressed air.





11. REMOVE PISTON SEAL
a. Using a screwdriver, remove the 2 piston seals from the disc brake cylinder assembly rear.
12. REMOVE REAR DISC BRAKE BLEEDER PLUG
a. Remove the rear disc brake bleeder plug from the disc brake cylinder assembly rear.





13. INSPECT DISC THICKNESS
a. Using a micrometer, measure the disc thickness.
Standard thickness: 16.0 mm (0.630 inch)
Minimum thickness: 14.5 mm (0.571 inch)
If the disc thickness is less than the minimum, replace the disc.
14. REMOVE PARKING BRAKE SHOE ADJUSTING HOLE PLUG
a. Remove the parking brake shoe adjusting hole plug from the rear disc.
15. REMOVE REAR DISC





a. Put matchmarks on the rear disc and the axle hub.





b. Release the parking brake, and remove the rear disc.

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

16. INSTALL REAR DISC
a. Aligning the matchmarks, install the rear disc.

HINT: When replacing the rear disc with a new one, select the installation position where the rear disc has the minimum runout.

17. INSTALL PARKING BRAKE SHOE ADJUSTING HOLE PLUG
a. Install the parking brake shoe adjusting hole plug to the rear disc.
18. INSPECT DISC RUNOUT





a. Tighten the disc with the 3 hub nuts.

HINT: Use SST 09330-00021 to hold the disc during measurement.

Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)





b. Using a dial indicator, measure the disc runout 10 mm inside (0.39 inch) the outer edge of the disc.
Maximum disc runout: 0.05 mm (0.0020 inch)
c. If the runout exceeds the maximum value, change the installation positions of the disc and axle so that the runout will become minimal. If the runout exceeds the maximum even when the installation positions are changed, check the bearing play in the axial direction and the axle hub runout. If the bearing play and the axle hub runout are normal and if the disc thickness is not within the specified range, shave the disc. If the disc thickness is less than the minimum, replace the disc.
19. ADJUST PARKING BRAKE SHOE CLEARANCE
20. TEMPORARILY TIGHTEN REAR DISC BRAKE BLEEDER PLUG
a. Temporarily install the rear disc brake bleeder plug to the disc brake cylinder assembly rear.
21. INSTALL PISTON SEAL
a. Apply lithium soap base glycol grease to a new piston seal.
b. Install the piston seal to the disc brake cylinder assembly rear.
22. INSTALL REAR DISC BRAKE PISTON
a. Apply lithium soap base glycol grease to the rear disc brake piston and a new cylinder boot.
b. Install the cylinder boot to the rear disc brake piston.
c. Install the rear disc brake piston to the disc brake cylinder assembly rear.

NOTICE:
^ Do not install the piston forcibly in the disc brake cylinder.

23. INSTALL CYLINDER BOOT
a. Install the cylinder boot to the disc brake cylinder assembly rear.

NOTICE:
^ Install the boot securely into the grooves of the cylinder and the piston.
^ Do not damage the cylinder boot.





24. INSTALL DISC BRAKE CYLINDER ASSEMBLY REAR LH
a. Install the disc brake cylinder assembly rear with 2 new bolts.
Torque: 78 Nm (800 kgf-cm, 58 ft. lbs.)

NOTICE: Since the bolted portion is an aluminum knuckle, keep it clean and avoid over tightening. Pull the disc brake cylinder assembly toward the outside of the vehicle to remove any play between the pin and knuckle hole. From this position tighten bolt 1 and then 2. Always follow these directions when installing.





25. CONNECT REAR LH FLEXIBLE HOSE
a. Connect the flexible hose with the union bolt and a new gasket.
Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.)

HINT: Install the flexible hose lock securely in the lock hole in the caliper.

26. INSTALL DISC BRAKE PAD KIT REAR (PAD ONLY)





a. Right wheel: Connect the pad wear indicator to the inner pads, and install a new clip.

NOTICE: Replace the pad wear indicator with a new one only if the wire probe is worn out and there is an open circuit.

HINT: Install the clip lock securely in the grooves of the pad.





b. Apply disc brake grease to the anti squeal shims and install them to each pad.

NOTICE:
^ When replacing worn pads, the anti squeal shims must be replaced together with the pads.
^ Install each shim in the correct position and direction.
^ There should be no oil or grease on the friction surface of the pads and the disc.

c. Install the pad wear indicator to the inner pad.

NOTICE: Install the pad wear indicator in the correct position and direction.





27. INSTALL REAR DISC BRAKE ANTI-RATTLE SPRING
28. INSTALL REAR DISC BRAKE W/HOLE PIN
a. Install the rear disc brake w/ hole pin while pushing on the rear disc brake anti-rattle spring.

HINT: Right wheel: Thread the pad wear indicator wire clamp through the rear disc brake w/ hole pin.

b. Install a new clip.
29. FILL RESERVOIR WITH BRAKE FLUID
30. BLEED MASTER CYLINDER
SST 09023-00101
31. BLEED BRAKE LINE
32. BLEED BRAKE ACTUATOR
33. CHECK BRAKE FLUID LEAKAGE
If fluid leaks, tighten or replace the leaking part.
34. CHECK FLUID LEVEL IN RESERVOIR
35. INSTALL REAR WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)