Drum Brake System: Service and Repair

REAR BRAKE
OVERHAUL

HINT: Overhaul the RH side by using the same procedures as those for the LH side.





1. INSPECT REAR DRUM BRAKE SHOE LINING THICKNESS
a. Remove the hole plug, and check the shoe lining thickness through the hole.
Minimum thickness: 1.0 mm (0.039 inch)
If the thickness is less than the minimum, replace the shoes.
2. REMOVE REAR WHEEL
3. DRAIN BRAKE FLUID

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

4. REMOVE REAR BRAKE DRUM SUB-ASSY
a. Release the parking brake lever, and remove the brake drum.

HINT: If the brake drum cannot be removed easily, perform the following procedures.





b. Remove the hole plug and insert a screwdriver into the hole on the backing plate, and hold the rear brake automatic adjust lever away from the adjuster.
c. Using another screwdriver, compress the brake shoe adjuster by turning the adjusting wheel.





5. INSPECT BRAKE DRUM INSIDE DIAMETER
a. Using a brake drum gauge or an 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)





6. SEPARATE PARKING BRAKE SHOE STRUT SET LH
a. Using SST, disconnect the shoe return spring from the front brake shoe and the rear brake shoe
SST 09703-30010

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





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





9. REMOVE REAR BRAKE AUTOMATIC ADJUST LEVER LH
a. Remove the rear brake automatic adjust lever tension spring and the rear brake automatic adjust lever.
10. REMOVE REAR BRAKE SHOE





a. Using SST, remove the shoe hold down spring cup, the shoe hold down spring and the pin.
SST 09718-00010





b. Using needle-nose pliers, disconnect the parking brake cable No.3 from the parking brake shoe lever.





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





12. INSPECT REAR DRUM BRAKE SHOE LINING THICKNESS
a. Using a ruler, measure the thickness of the shoe lining.
Standard thickness: 4.0 mm (0.157 inch)
Minimum thickness: 1.0 mm (0.039 inch)
If the lining thickness is equal to the minimum thickness or less, or there is severe or uneven wear, replace the brake shoe.





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 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.





14. REMOVE REAR WHEEL BRAKE CYLINDER ASSY
a. Using SST, disconnect the brake line.
SST 09023-00100

HINT: Use a container to catch the brake fluid.

b. Remove the bolt and the rear wheel brake cylinder assy.
15. REMOVE REAR WHEEL CYLINDER CUP KIT
a. Remove the 2 cylinder dust boots from the rear wheel brake cylinder.
b. Remove the 2 pistons and the compression spring.
c. Remove the 2 wheel cylinder cups from each piston.
16. INSPECT BRAKE WHEEL CYLINDER
a. Check the cylinder bore and the piston for rust or scoring.
17. REMOVE REAR DRUM BRAKE BLEEDER PLUG
a. Remove the rear drum brake bleeder plug from the rear wheel cylinder assy.





18. INSTALL REAR WHEEL CYLINDER CUP KIT
a. Apply lithium soap base glycol grease to new 2 wheel cylinder cups and the 2 pistons.
b. Install the 2 wheel cylinder cups on each piston.
c. Install the compression spring and the 2 pistons on the rear wheel brake cylinder.
d. Install the 2 new cylinder dust boots on the rear wheel brake cylinder.
19. TEMPORARILY TIGHTEN REAR DRUM BRAKE BLEEDER PLUG
a. Install the rear drum brake bleeder plug to the rear wheel cylinder assy.





20. INSTALL REAR WHEEL BRAKE CYLINDER ASSY
a. Install the rear wheel brake cylinder assy with the bolt.
Torque: 9.8 Nm (100 kgf-cm, 87 ft. lbs.)
b. Using SST, connect the brake line.
SST 09023-00100
Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.)





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





22. INSTALL REAR BRAKE PARKING BRAKE SHOE LEVER SUB-ASSY
a. Using a needle-nose pliers, install the parking brake lever with a new C-washer.
23. INSTALL REAR BRAKE SHOE





a. Using needle-nose pliers, connect the parking brake cable No.3 to the parking brake shoe lever.





b. Using SST, install the rear brake shoe, the pin, the shoe hold down spring and the shoe hold down cup.
SST 09718-00010





24. INSTALL REAR BRAKE AUTOMATIC ADJUST LEVER LH
a. Install the rear brake automatic adjust lever LH and the rear brake 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 LH as shown in the illustration.
26. INSTALL FRONT BRAKE SHOE





a. Connect the tension spring to the front brake shoe and rear brake shoe.
b. Using SST, install the front brake shoe, the pin, the shoe hold down spring and the cup.
SST 09718-00010





c. Using a needle-nose pliers, connect the tension spring to the front brake shoe and rear brake shoe.





27. CONNECT PARKING BRAKE SHOE STRUT SET LH
a. Using SST, connect the shoe return spring to the front brake shoe and rear brake shoe.
SST 09703-30010

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

28. CHECK REAR DRUM BRAKE INSTALLATION





a. Check that each part is installed properly.





b. Measure the brake drum inside diameter and the diameter of the brake shoes. Check the difference between the diameter is the correct shoe clearance.
Shoe clearance: 0.6 mm (0.024 inch)

NOTICE: There should be no oil or grease adhering to the friction surfaces of the shoe lining and the drum.

29. INSTALL REAR BRAKE DRUM SUB-ASSY
a. Install the rear brake drum sub-assy.





30. ADJUST REAR DRUM BRAKE SHOE CLEARANCE
a. Temporarily install the 2 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 09023-00100
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. CHECK PARKING BRAKE LEVER TRAVEL
38. ADJUST PARKING BRAKE LEVER TRAVEL