Parking Brake System: Service and Repair

DISASSEMBLY





1. REMOVE REAR WHEEL
2. REMOVE REAR BRAKE CALIPER ASSEMBLY
a. Remove the 2 mounting bolts and remove the brake caliper assembly.
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 FRONT SHOE ADJUSTER AND TENSION SPRING
a. Slide out the front shoe and remove the shoe adjuster.
b. Remove the shoe strut with the spring.
c. Remove the shoe hold-down spring, 2 cups and pin.
d. Disconnect the tension spring and remove the front shoe.





6. REMOVE REAR SHOE
a. Slide out the rear shoe.
b. Remove the tension spring from the rear shoe.
c. Remove the shoe hold-down spring, 2 cups and pin.
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 brake drum gauge or equivalent, measure the inside diameter of the disc.
Standard inside diameter: 170 mm (6.69 inch)
Maximum inside diameter: 171 mm (6.73 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 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.
b. Remove the shim and install the correct size shim.





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

REASSEMBLY





NOTICE: Apply high temperature grease to the parts indicated by the arrows.





1. INSTALL REAR SHOE
a. Using needle-nose pliers, connect the parking brake cable from the parking brake shoe lever.
b. Install the shoe hold down spring, 2 cups and pin.
c. Slide in the rear shoe.
d. Install the tension spring to the rear shoe.
2. INSTALL FRONT SHOE, SHOE ADJUSTER AND TENSION SPRING
a. Install the shoe hold-down spring, 2 cups and pin.
b. Install the shoe adjuster to the front shoe.
c. Slide in the front shoe, and install the shoe strut and spring.
d. Using needle-nose pliers, install the tension spring.





3. INSTALL SHOE RETURN SPRINGS
Using needle-nose pliers, install the 2 shoe return springs.
4. INSTALL DISC AND REAR BRAKE CALIPER
a. Install the disc and temporarily install the 3 hub nuts.
5. ADJUST PARKING BRAKE SHOE CLEARANCE
a. Remove the hole plug.





b. Turn the adjuster and expand the shoes until the disc locks.
c. Return the adjuster 8 notches.
d. Install the hole plug.
e. Install the rear brake caliper and 2 mounting bolts.
Torque: 47 Nm (475 kgf-cm, 34 ft. lbs.)
f. Remove the 3 hub nuts
6. INSTALL REAR WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
7. SETTLING PARKING BRAKE SHOES AND DISC
a. With the parking brake release button pushed in, pull the lever with 98 N (10 kgf, 22 lbs.) of force.
b. Drive the vehicle at about 50 km/h (31 mph) on a safe, level and dry road for about 400 meters (0.25 mile) in this condition.
c. Repeat this procedure 2 or 3 times.
8. RECHECK AND ADJUST PARKING BRAKE LEVER TRAVEL