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 the thickness is less than minimum, replace the shoes.
Minimum thickness: 1.0 mm (0.039 inch)
2. REMOVE REAR WHEEL
Torque: 104 Nm (1,050 kgf-cm, 77 ft. lbs.)





3. REMOVE BRAKE DRUM

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

a. Insert a screwdriver through the hole in the brake drum, and hold the automatic adjusting lever away from the adjuster.
b. Using another screwdriver, reduce the brake shoe adjuster by turning the adjuster.
4. REMOVE FRONT SHOE





a. Using pliers, disconnect the return spring from the automatic adjusting lever.
b. Remove the return spring from the rear shoe.
c. Remove the automatic adjusting lever.





d. Using SST, remove the shoe hold-down spring, cap and pin from the front shoe.
SST 09718-00010





e. Using SST, disconnect the anchor spring from the front shoe and remove the front shoe.
SST 09703-30010
f. Remove the adjuster.
g. Remove the anchor spring from the rear shoe.
5. REMOVE REAR SHOE
a. Using SST, remove the shoe hold-down spring, cap and pin.
SST 09718-00010
b. Using pliers, disconnect the parking brake cable from the parking brake lever and remove the rear shoe.
c. Using pliers, disconnect the parking brake cable from the parking brake lever and remove the rear shoe.
6. REMOVE PARKING BRAKE LEVER
a. Remove the C-washer and shim.
b. Remove the parking brake lever.





7. REMOVE WHEEL CYLINDER
a. 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.)
b. Remove the 2 bolts and the wheel cylinder.
Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.)
8. DISASSEMBLE WHEEL CYLINDER
a. Remove the 2 boots.
b. Remove the 2 pistons and spring.
c. Remove the 2 piston cups from the pistons.

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





2. MEASURE BRAKE SHOE LINING THICKNESS
Using a ruler, measure the shoe lining thickness.
Standard thickness: 6.0 mm (0.236 inch)
Minimum thickness: 1.0 mm (0.039 inch)
If the shoe lining is less than the minimum or shows signs of uneven wear, replace the brake shoes.

HINT: If a brake shoe needs replacing, the brake shoes must be replaced as a set.





3. MEASURE BRAKE DRUM INSIDE DIAMETER
Using a brake drum gauge or equivalent, measure the inside diameter of the drum.
Standard inside diameter: 250.0 mm (9.843 inch)
Maximum inside diameter: 252.0 mm (9.921 inch)
If the drum is scored or worn, the brake drum may be lathed to the maximum inside diameter.





4. INSPECT REAR 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 CLEARANCE BETWEEN BRAKE SHOES AND DRUM
a. Remove the brake 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: 0.5 mm (0.020 inch)
If incorrect, check the parking brake system.
2. FILL BRAKE RESERVOIR WITH BRAKE FLUID
3. BLEED BRAKE SYSTEM
4. CHECK FOR LEAKS