Rear

OVERHAUL

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

1. REMOVE REAR WHEEL
2. DRAIN BRAKE FLUID

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

3. DISCONNECT REAR LH FLEXIBLE HOSE
a. Remove the union bolt and the gasket from the disc brake cylinder assy rear, then disconnect the flexible hose.





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





5. REMOVE DISC BRAKE CYLINDER ASSY REAR LH
a. Remove the disc brake cylinder assy rear LH.
6. REMOVE DISC BRAKE PAD KIT REAR (PAD ONLY)
a. Remove the 2 brake pads with the anti squeal shim.
7. REMOVE ANTI SQUEAL SHIM KIT REAR
a. Remove the 4 anti squeal shims from each pad.
b. Using a screwdriver, remove the 2 pad wear indicators from each pad.
8. REMOVE REAR DISC BRAKE PAD SUPPORT PLATE
a. Remove the rear disc brake pad support plate (No.1) and the rear disc brake pad support plate (No.2) from the rear disc brake cylinder mounting LH.





9. REMOVE REAR DISC BRAKE BUSH DUST BOOT
a. Remove the 2 rear disc brake bush dust boots from the rear disc brake cylinder mounting LH.





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





11. REMOVE REAR DISC BRAKE CYLINDER SLIDE BUSH
a. Remove the rear disc brake cylinder slide bush from the rear disc brake cylinder slide pin No.2.

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





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

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





13. REMOVE REAR DISC BRAKE PISTON
a. Place a shop rug between the brake piston and the rear disc brake cylinder sub-assy.
b. Use compressed air to remove the brake piston from the rear disc brake cylinder sub-assy.

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

NOTICE: Do not spatter the brake fluid.





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

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

15. REMOVE REAR DISC BRAKE BLEEDER PLUG CAP
a. Remove the bleeder plug cap from the rear disc brake bleeder plug.
16. REMOVE REAR DISC BRAKE BLEEDER PLUG
a. Remove the rear disc brake bleeder plug from the rear disc brake cylinder sub-assy.
17. INSPECT BRAKE CYLINDER AND PISTON
a. Inspect the cylinder bore and the brake piston for rust or scoring.





18. INSPECT PAD LINING THICKNESS
a. Using a ruler, measure the pad lining thickness.
Standard thickness: 10.0 mm (0.394 inch)
Minimum thickness: 1.0 mm (0.039 inch)
19. INSPECT REAR DISC BRAKE PAD SUPPORT PLATE
a. Inspect the front disc brake pad support plate (No. 1) and the front disc brake pad support plate (No.2). Make sure that they have sufficient rebound, there are no deformation cracks or wear, and all rust and dirt are cleaned off.





20. INSPECT DISC THICKNESS
a. Using a micrometer, measure the disc thickness.
Standard thickness: 10.0 mm (0.394 inch)
Minimum thickness: 8.5 mm (0.335 inch)
21. 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 the shoe adjuster until the wheel turns freely.

22. REMOVE PARKING BRAKE SHOE ADJUSTING HOLE PLUG
a. Remove the parking brake shoe adjusting hole plug from the rear disc.
23. INSTALL PARKING BRAKE SHOE ADJUSTING HOLE PLUG
a. Install the parking brake shoe adjusting hole plug to the rear disc.
24. 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.





25. INSPECT DISC RUNOUT
a. Temporarily fasten the rear disc with hub nuts.
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
b. Using a dial gauge, 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)
c. If the disc runout is equal to 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 a "On-car" brake lathe.
26. ADJUST PARKING BRAKE SHOE CLEARANCE
27. TEMPORARILY TIGHTEN REAR DISC BRAKE BLEEDER PLUG
a. Temporarily install the rear disc brake bleeder plug to the rear disc brake cylinder sub-assy.
28. INSTALL REAR DISC BRAKE BLEEDER PLUG CAP
a. Install the rear disc brake bleeder plug cap to the rear disc brake bleeder plug.
29. 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-assy.





30. 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-assy.

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





31. INSTALL CYLINDER BOOT
a. Install the cylinder boot to the rear disc brake cylinder sub-assy.

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





32. INSTALL REAR DISC BRAKE CYLINDER SLIDE BUSH
a. Apply lithium soap base glycol grease to a new rear disc brake cylinder slide bush.
b. Install the rear disc brake cylinder slide bush to the rear disc brake cylinder slide pin No.2.





33. INSTALL REAR DISC BRAKE CYLINDER MOUNTING LH
a. Install the rear disc brake cylinder mounting LH with the 2 bolts.
Torque: 78 Nm (799 kgf-cm, 58 ft. lbs.)





34. INSTALL REAR DISC BRAKE BUSH DUST BOOT
a. Apply lithium soap base glycol grease to the seal surface of 2 new rear disc brake bush dust boots.
b. Install the 2 rear disc brake bush dust boots to the rear disc brake cylinder mounting LH.
35. INSTALL REAR DISC BRAKE PAD SUPPORT PLATE
a. Install the rear disc brake pad support plate (No.1) and the rear disc brake pad support plate (No.2) to the rear disc brake cylinder mounting LH.





36. 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.

37. INSTALL DISC BRAKE PAD KIT REAR (PAD ONLY)
a. Install the 2 brake pads w/ anti squeal shims to the rear disc brake cylinder mounting LH.

NOTICE: There should be no oil or grease on the friction surface of the pads and the disc.





38. INSTALL DISC BRAKE CYLINDER ASSY REAR LH
a. Install the rear disc brake cylinder assy rear LH.
39. INSTALL REAR DISK BRAKE CYLINDER SLIDE PIN





a. Apply the lithium soap base glycol grease to the sliding part and the seal surface of the 2 slide pins.
b. Install the rear disc brake cylinder slide pin.
c. Install the rear disc brake cylinder slide pin No.2 to the bottom side of the cylinder mounting LH.





d. Fully tighten the rear disc brake cylinder slide pin and the rear disc brake cylinder slide pin No.2.
Torque: 43 Nm (440 kgf-cm, 32 ft. lbs.)

40. CONNECT REAR LH FLEXIBLE HOSE
a. Connect the flexible hose with the union bolt and a new gasket.
Torque: 29 Nm (300 kgf-cm, 21 ft. lbs.)
41. FILL RESERVOIR WITH BRAKE FLUID
42. BLEED MASTER CYLINDER
SST 09023-00100
43. BLEED BRAKE LINE
44. BLEED BRAKE ACTUATOR ASSY
45. CHECK BRAKE FLUID LEAKAGE
46. CHECK FLUID LEVEL IN RESERVOIR
47. INSTALL REAR WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)