Rear

REAR BRAKE

COMPONENTS:

REMOVAL
1. REMOVE REAR WHEEL
2. DRAIN BRAKE FLUID
3. DISCONNECT REAR FLEXIBLE HOSE
a. Remove the union bolt and the gasket from the rear disc brake cylinder assembly, then disconnect the flexible hose.





4. REMOVE REAR DISC BRAKE CYLINDER SLIDE PIN NO. 2
a. Remove the rear disc brake cylinder slide pin No. 2.
5. REMOVE REAR DISC BRAKE CYLINDER SLIDE PIN NO. 1
a. Remove the rear disc brake cylinder slide pin No. 1.





6. REMOVE REAR DISC BRAKE CYLINDER ASSEMBLY
a. Remove the rear disc brake cylinder assembly.

DISASSEMBLY
1. REMOVE DISC BRAKE PAD KIT REAR (PAD ONLY)
2. REMOVE ANTI-SQUEAL SHIM KIT REAR
a. Remove the 2 anti-squeal shims and the pad wear indicator plate from each pad.
3. REMOVE REAR DISC BRAKE PAD SUPPORT PLATE NO. 1
a. Remove the rear disc brake pad support plate No. 1 from the rear disc brake cylinder mounting.
4. REMOVE REAR DISC BRAKE PAD SUPPORT PLATE NO. 2
a. Remove the rear disc brake pad support plate No. 2 from the rear disc brake cylinder mounting.





5. REMOVE REAR DISC BRAKE BUSHING DUST BOOT
a. Remove the 2 rear disc brake bushing dust boots from the rear disc brake cylinder mounting.





6. REMOVE REAR DISC BRAKE CYLINDER SLIDE BUSHING
a. Remove the rear disc brake cylinder slide bushing from the rear disc brake cylinder slide pin No. 2.

NOTICE: Do not damage the front disc brake cylinder slide pin No. 2.

HINT: Tape the screwdriver tip before use.





7. REMOVE REAR DISC BRAKE CYLINDER MOUNTING
a. Remove the 2 bolts and the rear disc brake cylinder mounting.





8. REMOVE CYLINDER BOOT
a. Using a screwdriver, remove the cylinder boot.

HINT: Tape the screwdriver tip before use.

9. REMOVE REAR DISC BRAKE PISTON
a. Place a shop rug or a piece of cloth between the brake piston and the rear disc brake cylinder subassembly.





b. Use compressed air to remove the piston from the disc brake cylinder assembly.

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

NOTICE: Do not spatter the brake fluid.





10. REMOVE PISTON SEAL
a. Using a screwdriver, remove the piston seal from the rear disc brake cylinder sub-assembly.

NOTICE: Do not damage the inner cylinder and the cylinder groove.

HINT: Tape the screwdriver tip before use.

11. REMOVE REAR DISC BRAKE BLEEDER PLUG CAP
a. Remove the bleeder plug cap from the rear disc brake bleeder plug.
12. REMOVE REAR DISC BRAKE BLEEDER PLUG
a. Remove the rear disc brake bleeder plug from the rear disc brake cylinder sub-assembly.





13. 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 and press firmly the shoe adjuster until the wheel comes free.

REASSEMBLY





1. 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.

2. INSPECT DISC RUNOUT
a. Before measuring the rear disc runout, check the rear wheel bearing play and the rear axle hub runout.
b. Temporarily fasten the rear disc with hub nuts.
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)





c. Using a dial indicator, measure the disc runout 10 mm (0.39 inch) away from the outer edge of the rear disc.
Maximum disc runout: 0.15 mm (0.0059 inch)
d. If the disc runout is equal to the maximum value or greater, check the bearing play in the axial direction and check the axle hub runout. If the bearing play and axle hub runout are not abnormal, adjust the disc runout or grind it on an on-car brake lathe.
3. ADJUST PARKING BRAKE SHOE CLEARANCE

HINT: Hold the rear disc with hub nuts before adjusting the parking brake shoe clearance.

4. TEMPORARILY TIGHTEN REAR DISC BRAKE BLEEDER PLUG
a. Temporarily install the rear disc brake bleeder plug to the rear disc brake cylinder sub-assembly.
5. INSTALL REAR DISC BRAKE BLEEDER PLUG CAP
a. Install the rear disc brake bleeder plug cap to the rear disc brake bleeder plug.
6. INSTALL PISTON SEAL
a. Apply lithium soap base glycol grease to a new piston seal.
b. Install the piston seal to the rear disc brake cylinder sub-assembly.





7. 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 piston to the rear disc brake cylinder sub assembly.

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





8. INSTALL CYLINDER BOOT
a. Install the cylinder boot to the rear disc brake cylinder sub-assembly.

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





9. INSTALL REAR DISC BRAKE CYLINDER MOUNTING
a. Install the rear disc brake cylinder mounting with the 2 bolts.
Torque: 78 Nm (800 kgf-cm, 56 ft. lbs.)
10. INSTALL REAR DISC BRAKE BUSHING DUST BOOT
a. Apply lithium soap base glycol grease to the seal surface of 2 new rear disc brake bushing dust boots.





b. Install the 2 rear disc brake bushing dust boots to the rear disc brake cylinder mounting.





11. INSTALL REAR DISC BRAKE CYLINDER SLIDE BUSHING
a. Apply lithium soap base glycol grease to a new rear disc brake cylinder slide bushing.
b. Install the rear disc brake cylinder slide bushing to the rear disc brake cylinder slide pin No. 2.
12. INSTALL REAR DISC BRAKE PAD SUPPORT PLATE NO. 1
a. Install the rear disc brake pad support plate No. 1 to the rear disc brake cylinder mounting.
13. INSTALL REAR DISC BRAKE PAD SUPPORT PLATE NO. 2
a. Install the rear disc brake pad support plate No. 2 to the rear disc brake cylinder mounting.
14. INSTALL ANTI-SQUEAL SHIM KIT REAR
a. Apply disc brake grease to the inside of the anti-squeal shims and install them and the pad wear indicators to each of the 2 brake pads.

NOTICE:
^ When replacing worn pads, the anti-squeal shims must be replaced together with the pads.
^ Install the pad wear indicator and anti-squeal shims in the correct positions and directions.





b. Install the 2 anti-squeal shims and the pad wear indicator plate to each pad.
15. INSTALL DISC BRAKE PAD KIT REAR (PAD ONLY)
a. Install the 2 brake pads with anti-squeal shims to the rear disc brake cylinder mounting.

INSTALLATION





1. INSTALL REAR DISC BRAKE CYLINDER ASSEMBLY
a. Install the rear disc brake cylinder assembly.

NOTICE: Install the rear disc brake bush dust boot onto the groove of the rear disc brake cylinder.

2. INSTALL REAR DISC BRAKE CYLINDER SLIDE PIN NO. 1
a. Apply the lithium soap base glycol grease to the sliding part and the seal surface of the slide pin.





b. Install the rear disc brake cylinder slide pin No. 1.
Torque: 43 Nm (440 kgf-cm, 32 ft. lbs.)
3. INSTALL REAR DISC BRAKE CYLINDER SLIDE PIN NO. 1
a. Apply the lithium soap base glycol grease to the sliding part and the seal surface of the slide pin No. 2.
b. Install the rear disc brake cylinder slide pin No. 2.
Torque: 43 Nm (440 kgf-cm, 32 ft. lbs.)
4. CONNECT REAR FLEXIBLE HOSE
a. Connect the flexible hose with the union bolt and a new gasket.
Torque: 29 Nm (300 kgf-cm, 21 ft. lbs.)
5. ADD RESERVOIR WITH BRAKE FLUID
6. BLEED REAR BRAKE SYSTEM
7. PERFORM ACCUMULATOR ZERO DOWN
8. CHECK BRAKE FLUID LEVEL
9. CHECK BRAKE FLUID LEAKAGE
10. INSTALL REAR WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
11. CLEAR DTC