Drum Brake System: Service and Repair

REMOVAL





1. INSPECT SHOE LINING THICKNESS
Remove the inspection hole plug, and check the shoe lining thickness through the hole.
If it is less than minimum, replace the shoes.
Minimum thickness: 1.0 mm (0.039 inch)
2. REMOVE REAR WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)





3. REMOVE BRAKE DRUM
(a) Release the parking brake lever and remove the brake drum.

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

(b) Remove the adjusting hole plug in the backing plate.
(c) Insert a screwdriver through the hole in the backing plate, and hold the automatic adjusting lever away from the adjusting bolt.
(d) Using another screwdriver, reduce the brake shoe adjustment by turning the adjusting bolt.
4. REMOVE FRONT SHOE





(a) Using SST, disconnect the return spring.
SST 09703-30010





(b) Using SST, remove the shoe hold-down spring, 2 cups and pin.
SST 09718-00010
(c) Disconnect the anchor spring from the front shoe and remove the front shoe.
(d) Remove the anchor spring from the rear shoe.





5. REMOVE ADJUSTER AND REAR SHOE
(a) Using SST, remove the shoe hold~own spring, 2 cups and pin.
SST 09718-00010
(b) Remove the adjusting lever spring.
(c) Remove the adjuster together with the return spring.
(d) Using pliers, disconnect the parking brake cable from the lever and remove the rear shoe.

Remove E-Ring And C-Washer:

6. REMOVE AUTOMATIC ADJUSTING LEVER AND PARKING BRAKE LEVER
(a) Remove the E-ring.
(b) Remove the automatic adjusting lever.
(c) Remove the C-washer.
(d) Remove the parking brake lever.





7. DISCONNECT BRAKE LINE FROM WHEEL CYLINDER
Using SST, disconnect the brake line. Use a container to catch the brake fluid.
SST 09023-00100
Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.)
8. REMOVE WHEEL CYLINDER
Remove the 2 bolts and wheel cylinder.
Torque: 10 Nm (100 kgf-cm, 7 ft. lbs.)
9. DISASSEMBLE WHEEL CYLINDER
(a) Remove the 2 boots, 2 pistons and spring.
(b) Remove the 2 piston cups from each piston.

INSPECTION
1. INSPECT DISASSEMBLED PARTS
Inspect the disassembled part for wear, rust or damage.





2. MEASURE BRAKE DRUM INSIDE DIAMETER
Using a brake drum gauge or equivalent, measure the inside diameter of the drum.
Standard inside diameter: 254.0 mm (10.000 inch)
Maximum inside diameter: 256.0 mm (10.079 inch)
If the drum is scored or worn, the brake drum may be lathed to the maximum inside diameter.

Fig. 4 Measuring Brake Shoe Lining Thickness:

3. MEASURE BRAKE SHOE LINING THICKNESS
Using a ruler, measure the shoe lining thickness.
Standard thickness: 5.6 mm (0.220 inch)
Minimum thickness: 1.0 mm (0.039 inch)
If the shoe lining is less than 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.





4. INSPECT BRAKE LINING AND DRUM FOR PROPER CONTACT
If the contact between the brake lining and drum is improper, repair the lining with a brake shoe grinder, or replace the brake shoe assembly.

INSTALLATION
Installation is in the reverse order of removal.

NOTICE: Apply lithium soap base glycol grease and high temperature grease to the parts indicated by the arrows.

1. CHECK OPERATION OF AUTOMATIC ADJUSTER MECHANISM





(a) Move the parking brake lever of the rear shoe back and forth. Check that the adjusting bolt turns.
If it does not turn, check for incorrect installation of the rear brakes.





(b) Adjust the adjuster length to the shortest possible amount.
(c) Install the drum.
(d) Pull the parking brake lever all the way up until a clicking sound can no longer be heard.





2. CHECK CLEARANCE BETWEEN BRAKE SHOES AND DRUM
(a) Remove the drum.
(b) Measure the brake drum inside diameter and diameter of the brake shoes. Check that the difference between the diameters is the correct shoe clearance.
Shoe clearance: 0.6 mm (0.024 inch)
If it is incorrect, check the parking brake system.
3. FILL BRAKE RESERVOIR WITH BRAKE FLUID
4. BLEED BRAKE SYSTEM
5. CHECK FOR LEAKS