Up to 08/2009

BRAKE (REAR): REAR BRAKE: INSTALLATION

HINT
* Use the same procedure for the RH side and LH side.
* The following procedure is for the LH side.
1. INSTALL REAR DISC

(a) Align the matchmarks and install the rear disc.





Text in Illustration





NOTICE:
When replacing the rear disc with a new one, select the installation position where the rear disc has minimal runout.

2. INSTALL PARKING BRAKE SHOE ADJUSTING HOLE PLUG

(a) Install the parking brake shoe adjusting hole plug.

3. INSTALL REAR DISC BRAKE CYLINDER MOUNTING

(a) Install the rear disc brake cylinder mounting to the rear axle carrier sub-assembly with the 2 bolts.





Torque : 78 Nm (799 kgf-cm, 58 ft-lbf)

4. INSTALL REAR DISC BRAKE BUSHING DUST BOOT

(a) Apply a light layer of lithium soap base glycol grease to the entire circumference of 2 new rear disc brake bushing dust boots.





HINT
Apply at least 0.3 g (0.01 oz.) of lithium soap base glycol grease to each rear disc brake bushing dust boot.

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





5. INSTALL NO. 2 REAR DISC BRAKE CYLINDER SLIDE PIN

(a) Apply a light layer of lithium soap base glycol grease to the sliding part and the seal surface of the No. 2 rear disc brake cylinder slide pin.





(b) Install the No. 2 rear disc brake cylinder slide pin to the rear brake cylinder mounting.





(c) Push the No. 2 rear disc brake cylinder slide pin into the rear disc brake bushing dust boot to align them.

6. INSTALL REAR DISC BRAKE CYLINDER SLIDE BUSHING

(a) Apply a light layer of lithium soap base glycol grease to the contact surface of the No. 1 rear disc brake cylinder slide pin.





(b) Install a new rear disc brake cylinder slide bushing to the No. 1 rear disc brake cylinder slide pin.

7. INSTALL NO. 1 REAR DISC BRAKE CYLINDER SLIDE PIN

(a) Apply a light layer of lithium soap base glycol grease to the sliding part and the seal surface of the No. 1 rear disc brake cylinder slide pin.





(b) Install the No. 1 rear disc brake cylinder slide pin to the rear disc brake cylinder mounting.





(c) Push the No. 1 rear disc brake cylinder slide pin into the rear disc brake bushing dust boot to align them.

8. INSTALL REAR DISC BRAKE PAD SUPPORT PLATE

(a) Install the 2 No. 1 rear disc brake pad support plates and 2 No. 2 rear disc brake pad support plates to the rear disc brake cylinder mounting.





Text in Illustration





NOTICE:
Be sure to install the No. 1 rear disc brake pad support plate and No. 2 rear disc brake pad support plate to the correct positions and directions.

9. INSTALL PAD WEAR INDICATOR PLATE

(a) Install the 2 pad wear indicators to the rear disc brake pads.





NOTICE:
Install the pad wear indicator plates in the correct positions and directions.

10. INSTALL REAR DISC BRAKE ANTI-SQUEAL SHIM

(a) Apply disc brake grease to the inside of the 2 rear disc brake anti-squeal shims as shown in the illustration.





NOTICE:
* When replacing worn pads, the rear disc brake anti-squeal shims must be replaced together with the pads.
* Apply disc brake grease to the area that contacts the rear disc brake anti-squeal shims.
* Disc brake grease can come out slightly from the area where the rear disc brake anti-squeal shims are installed.
* Make sure that disc brake grease is not applied onto the lining surface.
(b) Install the rear disc brake anti-squeal shims to each of the 2 rear disc brake pads.





NOTICE:
Install the shims in the correct positions and directions.

11. INSTALL REAR DISC BRAKE PAD

(a) Install the 2 rear disc brake pads to the rear disc brake cylinder mounting.





12. INSTALL REAR DISC BRAKE CYLINDER ASSEMBLY

(a) Hold the 2 rear disc brake cylinder slide pins and install the rear disc brake cylinder assembly to the rear disc brake cylinder mounting with the 2 bolts.

Torque : 27 Nm (270 kgf-cm, 20 ft-lbf)





Text in Illustration





13. CONNECT REAR FLEXIBLE HOSE

(a) Connect the rear flexible hose to the rear disc brake cylinder assembly with the union bolt and a new gasket.





Torque : 30 Nm (306 kgf-cm, 22 ft-lbf)

14. BLEED BRAKE LINE Service and Repair

15. ADJUST PARKING BRAKE SHOE CLEARANCE AND PARKING BRAKE PEDAL TRAVEL Adjustments

16. INSTALL REAR WHEEL

Torque : 103 Nm (1050 kgf-cm, 76 ft-lbf)