Parking Brake System: Service and Repair

DISASSEMBLY






1. REMOVE REAR WHEEL





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

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 2 shoe return springs.

5. REMOVE SHOE STRUT WITH SPRING





6. REMOVE FRONT SHOE AND ADJUSTER
a. Slide out the front shoe and remove the shoe adjuster.
b. Disconnect the tension spring and remove the front shoe.





7. REMOVE REAR SHOE AND TENSION SPRING
a. Slide out the rear shoe.
b. Remove the tension spring from the rear shoe.
c. Remove the 4 shoe hold-down spring cups, springs and pins.
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
Using a ruler, measure the thickness of the shoe lining.
Standard thickness: 2.0 mm (0.079 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, uneven wear, replace the brake shoe.





3. MEASURE DISC INSIDE DIAMETER
Using a vernier calipers, measure the inside diameter of the disc.
Standard inside diameter: 170.0 mm (6.690 inch)
Maximum inside diameter: 171.0 mm (6.732 inch)
Replace the disc if the inside diameter is at the maximum value or more. Replace the disc or grind it with a lathe if the disc is scored or is worn unevenly.





4. INSPECT PARKING BRAKE LINING AND DISC FOR PROPER CONTACT
Apply chalk to the inside surface of the disc, then grind down the brake shoe lining to fit. If the contact between the disc and the brake shoe lining is improper, repair it using a brake shoe grinder or replace the brake shoe assembly.





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.
c. Install a new C-washer.
d. Remeasure the clearance.

REASSEMBLY
1. APPLY HIGH TEMPERATURE GREASE TO THESE PARTS:
a. Rubbing surface of the backing plate and shoe.
b. Adjuster

2. CONNECT PARKING BRAKE CABLE TO PARKING BRAKE LEVER
a. Install the shoe hold-down springs, cups and pins.
b. Connect the parking brake cable to the parking brake shoe lever of the rear shoe.

3. INSTALL REAR SHOE
Slide in the rear shoe between the shoe hold-down spring cup and the backing plate.
NOTICE: Do not allow oil or grease to get on the rubbing face.

4. INSTALL TENSION SPRINGS, FRONT SHOE AND ADJUSTER
a. Install the tension spring on the rear shoe.
b. Install the front shoe on the tension spring.
c. Slide in the front shoe between the shoe hold-down spring cup and the backing plate.

5. INSTALL STRUT WITH SPRING
Install the strut with the spring forward.

6. INSTALL SHOE RETURN SPRINGS
Using needle-nose pliers, install the shoe return springs.

7. INSTALL DISC
a. Before installing, polish the disc and shoe surfaces with sandpaper.
b. Align the hole on the rear axle hub and service hole on the disc.

8. 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.

8. INSTALL REAR DISC BRAKE ASSEMBLY
Install the disc brake assembly and torque the 2 mounting bolts.
TORQUE: 47 Nm (475 kgf-cm, 34 ft. lbs.)

10. INSTALL REAR WHEEL

11. SETTLING PARKING BRAKE SHOES AND DISC
a. Drive the vehicle at about 50 km/h (31 mph) on a safe, level and dry road.
b. With the parking brake release button pushed in, pull on the lever with 98 N (10 kgf, 19.8 lbs.) of force.
c. Drive the vehicle for about 400 meters (0.25 mile) in this condition.
d. Repeat this procedure 2 or 3 times.
12. CHECK AND ADJUST PARKING BRAKE LEVER TRAVEL