Drum Brake System: Service and Repair

REAR DRUM BRAKE
OVERHAUL

HINT:
^ Overhaul the RH side by the same procedures with LH side.

1. REMOVE REAR WHEEL
2. DRAIN BRAKE FLUID

NOTICE: Wash off the brake fluid immediately if it comes into contact with a painted surface.





3. REMOVE REAR BRAKE DRUM SUB-ASSEMBLY

HINT: If the brake drum cannot be removed easily, do the following steps.

a. Insert a bent wire or equivalent through the hole in the brake drum, and hold the automatic adjusting lever away from the adjuster.
b. Using a screwdriver, reduce the brake shoe adjustment by turning the adjuster.
c. Remove the rear brake drum sub-assembly.





4. INSPECT BRAKE DRUM INSIDE DIAMETER
a. Using a brake drum gauge or equivalent, measure the in side diameter of the drum.
Standard inside diameter: 228.0 mm (8.976 inch)
Maximum inside diameter: 230.6 mm (9.079 inch)
5. REMOVE TENSION SPRING
a. Remove the tension spring from the front brake shoe and rear brake shoe.





6. SEPARATE PARKING BRAKE SHOE STRUT SET LH
a. Using SST, disconnect the shoe return spring and separate the parking brake shoe strut set LH.
SST 09703-30010

NOTICE: Do not damage the wheel cylinder boot.





7. REMOVE FRONT BRAKE SHOE
a. Using SST, remove the 2 cups, shoe hold-down spring and pin.
SST 09718-00010
b. Remove the front brake shoe.
8. REMOVE PARKING BRAKE SHOE STRUT SET LH





9. REMOVE REAR BRAKE SHOE
a. Using SST, remove the 2 cups, shoe hold-down spring and pin.
SST 09718-00010
b. Using a screwdriver, disconnect the parking brake cable from the anchor plate.
c. Using needle-nose pliers, disconnect the parking brake cable from the lever and remove the rear shoe.

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





10. REMOVE REAR BRAKE AUTOMATIC ADJUST LEVER LH
a. Remove the adjusting lever spring.
b. Remove the E-ring.
c. Remove the automatic adjusting lever.





11. REMOVE PARKING BRAKE SHOE LEVER LH
a. Using screwdriver, remove the C-washer and parking brake shoe lever.





12. INSPECT REAR DRUM BRAKE SHOE LINING THICKNESS
a. Using a ruler, measure the shoe lining thickness.
Standard thickness: 5.0 mm (0.197 inch)
Minimum thickness: 1.0 mm (0.039 inch)
If the thickness is less than the 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.





13. INSPECT BRAKE DRUM AND REAR DRUM BRAKE SHOE LINING FOR PROPER CONTACT
a. Apply chalk to the inside surface of the drum, then grind drum 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 assembly.





14. REMOVE LH, FRONT OR UPPER REAR WHEEL BRAKE CYLINDER ASSEMBLY
a. Using SST, disconnect the brake tube, use a container to catch brake fluid.
SST 09751-36011
b. Remove the 2 bolts and wheel cylinder.
15. REMOVE REAR WHEEL CYLINDER CUP KIT
a. Remove the 2 cylinder dust boots from the wheel cylinder.
b. Remove the 2 pistons and compression spring.
c. Remove the 2 cups from the each piston.
16. INSPECT BRAKE WHEEL CYLINDER
a. Check the cylinder bore and piston for rust or scoring.
17. REMOVE REAR DISC BRAKE BLEEDER PLUG CAP
18. REMOVE REAR DISC BRAKE BLEEDER PLUG
19. TEMPORARILY TIGHTEN REAR DISC BRAKE BLEEDER PLUG
20. INSTALL REAR DISC BRAKE BLEEDER PLUG CAP
21. INSTALL REAR WHEEL CYLINDER CUP KIT
a. Apply the lithium soap base glycol grease to the parts indicates by arrows.
b. Install the 2 wheel cylinder cups to each piston.
c. Install the compression spring and 2 pistons to the wheel cylinder.
d. Install are 2 new cylinder dust boots to the wheel cylinder.





22. INSTALL LH, FRONT OR UPPER REAR WHEEL BRAKE CYLINDER ASSEMBLY
a. Install the wheel cylinder with the 2 bolts.
Torque: 10 Nm (100 kgf-cm, 7 ft. lbs.)
b. Using SST, connect the brake tube.
SST 09751-36011
Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.)
23. APPLICATION HIGH TEMPERATURE GREASE
a. Apply the high temperature grease to the parts indicates by arrows.





24. INSTALL PARKING BRAKE SHOE LEVER LH
a. Install the parking brake shoe lever with a new C-washer.





25. INSTALL REAR BRAKE AUTOMATIC ADJUST LEVER LH
a. Install the automatic adjust lever and automatic adjust lever spring to the rear brake shoe with the E-ring.





26. INSTALL REAR BRAKE SHOE
a. Using needle-nose pliers, connect the parking brake cable to the parking brake shoe lever.
b. Using a screwdriver, connect the paring brake cable to the anchor plate.
c. Using SST, install the rear brake shoe, pin, shoe hold down spring and 2 cups.
SST 09718-00010
27. INSTALL PARKING BRAKE SHOE STRUT SET LH
a. Apply the high temperature grease to the part indicated by arrow.





b. Install the parking brake shoe strut set LH as shown in the installation.
c. Connect the shoe return spring to the rear shoe.





28. INSTALL FRONT BRAKE SHOE
a. Using SST, install the front brake shoe, pin, shoe hold down spring and cup.
SST 09718-00010





29. CONNECT PARKING BRAKE SHOE STRUT SET LH
a. Using SST, connect the tension spring to the front and rear brake shoe.
SST 09703-30010
30. INSTALL TENSION SPRING
a. Connect the tension spring to the front brake shoe.





31. 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.

32. INSTALL REAR BRAKE DRUM SUB-ASSEMBLY





33. ADJUST REAR DRUM BRAKE SHOE CLEARANCE

HINT: If the brake drum cannot be removed easily, do the following steps.

a. Insert a bent wire or equivalent through the hole in the brake drum, and hold the automatic adjusting lever away from the adjuster.
b. Using a screwdriver, reduce the brake shoe adjustment by turning the adjuster.
34. FILL RESERVOIR WITH BRAKE FLUID
35. BLEED MASTER CYLINDER
SST 09023-00101
36. BLEED BRAKE LINE
37. CHECK FLUID LEVEL IN RESERVOIR
38. CHECK BRAKE FLUID LEAKAGE
39. INSTALL REAR WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
40. CHECK PARKING BRAKE LEVER TRAVEL (LEVER TYPE PARKING BRAKE)
41. CHECK PARKING BRAKE PEDAL TRAVEL (PEDAL TYPE PARKING BRAKE)
42. ADJUST PARKING BRAKE LEVER TRAVEL (LEVER TYPE PARKING BRAKE)
43. ADJUST PARKING BRAKE PEDAL TRAVEL (PEDAL TYPE PARKING BRAKE)