TMC Made

REAR DRUM BRAKE (TMC MADE)





COMPONENTS

OVERHAUL

HINT: Use the same procedures for the RH side and LH side. The procedures listed below are for the LH side.

1. REMOVE REAR WHEEL
2. DRAIN BRAKE FLUID

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





3. REMOVE REAR BRAKE DRUM SUB-ASSEMBLY
a. Put matchmarks on the rear brake drum sub-assembly and the axle hub.
b. Release the parking brake and remove the rear brake drum sub-assembly.

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





c. Remove the hole plug and insert a screwdriver through the hole in the backing plate, and hold the automatic adjusting lever away from the adjuster.
d. Using another screwdriver, contract the brake shoe adjuster by turning the adjusting bolt.





4. INSPECT BRAKE DRUM INSIDE DIAMETER
a. Using a brake drum gauge or equivalent, measure the inside diameter of the drum.
Standard inside diameter: 200.0 mm (7.874 inch)
Maximum inside diameter: 201.0 mm (7.913 inch)

HINT: If the inside diameter of the brake drum is at the maximum or more, replace the brake drum sub-assembly.





5. SEPARATE PARKING BRAKE SHOE STRUT SET LH
a. Using SST, separate the spring and shoe strut set from the brake shoes.
SST 09703-30011

NOTICE: Be careful not to damage the cylinder dust boot.





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





8. REMOVE AUTOMATIC ADJUST LEVER LH
a. Remove the tension spring and the automatic adjust lever.





9. REMOVE REAR BRAKE SHOE
a. Using SST, remove the cup, shoe hold-down spring and pin.
SST 09718-00010





b. Using needle-nose pliers, separate the parking brake cable No.3 and remove the rear brake shoe.





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





11. INSPECT REAR DRUM BRAKE SHOE LINING THICKNESS
a. Using a ruler, measure the thickness of the shoe lining.
Standard thickness: 4.4 mm (0.173 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 or uneven wear, replace the brake shoe.





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





13. REMOVE REAR WHEEL BRAKE CYLINDER ASSEMBLY
a. Using SST, disconnect the brake line.
SST 09023-00101

HINT: Use a container to catch the brake fluid.

b. Remove the bolt and the wheel brake cylinder assembly.
14. REMOVE REAR WHEEL CYLINDER CUP KIT
a. Remove the 2 cylinder dust boots from the wheel brake cylinder assembly.
b. Remove the 2 pistons and the compression spring.
c. Remove the 2 wheel cylinder cups from each piston.
15. INSPECT BRAKE WHEEL CYLINDER
a. Check the cylinder bore and the piston for rust or scoring. If necessary, replace the brake wheel cylinder assembly.
16. REMOVE REAR DRUM BRAKE BLEEDER PLUG
a. Remove the bleeder plug from the wheel brake cylinder assembly.
17. TEMPORARILY TIGHTEN REAR DRUM BRAKE BLEEDER PLUG
a. Install the bleeder plug to the wheel brake cylinder assembly.





18. INSTALL REAR WHEEL CYLINDER CUP KIT
a. Apply lithium soap base glycol grease to 2 new wheel cylinder cups and 2 pistons.
b. Install the 2 wheel cylinder cups on each piston.
c. Install the compression spring and the 2 pistons to the wheel brake cylinder.
d. Install the 2 new cylinder dust boots to the wheel brake cylinder.





19. INSTALL REAR WHEEL BRAKE CYLINDER ASSEMBLY
a. Install the wheel brake cylinder assembly with the bolt.
Torque: 9.8 Nm (100 kgf-cm, 87 inch lbs.)
b. Using SST, connect the brake line.
SST 09023-00101
Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.)





20. APPLY HIGH TEMPERATURE GREASE
a. Apply high temperature grease to the shoe attached surface of the backing plate.





21. INSTALL PARKING BRAKE SHOE LEVER LH
a. Using needle-nose pliers, install the parking brake shoe lever sub-assembly with a new C-washer.





22. INSTALL REAR BRAKE SHOE
a. Using needle-nose pliers, connect the parking brake cable No.3 to the parking brake shoe lever sub-assembly.





b. Using SST, install the brake shoe, the pin, the shoe hold down spring and the shoe hold-down cup.
SST 09718-00010
23. INSTALL REAR BRAKE SHOE RETURN SPRING
a. Install the shoe return spring to the brake shoe.





24. INSTALL AUTOMATIC ADJUST LEVER LH
a. Install the automatic adjust lever and the automatic adjust lever tension spring to the front brake shoe.





25. INSTALL PARKING BRAKE SHOE STRUT SET LH
a. Apply high temperature grease to the adjusting bolt and assemble.
b. Install the shoe return spring to the strut set.





c. Install the parking brake shoe strut set as shown in the illustration.





26. INSTALL FRONT BRAKE SHOE
a. Install the tension spring to the brake shoes.
b. Using SST, install the front brake shoe, the pin, the shoe hold-down spring and the cup.
SST 09718-00010





27. INSTALL PARKING BRAKE SHOE STRUT SET LH
a. Using SST, install the shoe return spring to the brake shoes.
SST 09703-30011

NOTICE: Be careful not to damage the wheel cylinder boot.

28. 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.





If they are not installed correctly, reinstall them as shown in the illustration.
29. INSTALL REAR BRAKE DRUM SUB-ASSEMBLY
a. Aligning the matchmarks, install the rear brake drum sub-assembly.
30. ADJUST REAR DRUM BRAKE SHOE CLEARANCE
a. Temporarily install the hub nuts.





b. Remove the hole plug, and turn the adjuster to expand the shoe until the drum locks.
c. Rotate the adjuster by 8 notches.
d. Install the hole plug.
31. FILL RESERVOIR WITH BRAKE FLUID
32. BLEED MASTER CYLINDER SST 09023-00101
33. BLEED BRAKE LINE
34. CHECK FLUID LEVEL IN RESERVOIR
35. CHECK FOR BRAKE FLUID LEAKAGE
36. INSTALL REAR WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
37. INSPECT PARKING BRAKE LEVER TRAVEL
38. ADJUST PARKING BRAKE LEVER TRAVEL