Overhaul

REAR DRUM BRAKE

COMPONENTS:

DISASSEMBLY
1. REMOVE REAR WHEEL
2. DRAIN BRAKE FLUID

NOTICE: Wash the brake fluid off immediately if it attaches to any painted surface.

3. REMOVE REAR BRAKE DRUM SUB-ASSEMBLY
(a) Release the parking brake lever, and remove the rear brake drum.

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

(b) Remove the hole plug and insert a screwdriver through the hole in the backing plate, and hold the automatic adjusting lever away from the adjuster.
(c) Using another screwdriver, reduce the brake shoe adjuster by turning the adjusting wheel.

4. REMOVE FRONT BRAKE SHOE
(a) Using SST, remove the shoe return spring from the front brake shoe.
SST 09921-00010

(b) Using a needle-nose pliers, remove the return spring.

(c) Using SST, remove the shoe hold down spring cup, shoe hold down spring and pin.
SST 09718-00010
(d) Remove the parking brake shoe strut LWR.
(e) Remove the tension spring and front brake shoe.
(f) Remove the automatic adjust lever spring and rear brake automatic adjust lever LH from the front brake shoe.

5. REMOVE REAR BRAKE SHOE
(a) Using SST, remove the shoe hold down spring cup, shoe hold down spring and pin.
SST 09718-00010

(b) Using a needle-nose pliers, disconnect the parking brake cable No. 3 and remove the rear brake shoe.

(c) Using a screwdriver, remove the 2 C-washers, parking brake shoe lever, parking brake reaction lever LH and rear brake strut set.
6. REMOVE LH, FRONT OR UPPER REAR WHEEL BRAKE CYLINDER ASSEMBLY
(a) Using SST, disconnect the brake tube, use a container to catch the brake fluid.
SST 09023-00101

(b) Remove the 2 bolts and rear wheel brake cylinder assembly.
7. REMOVE REAR WHEEL CYLINDER CUP KIT
(a) Remove the 2 cylinder dust boots from the rear wheel brake cylinder assembly.
(b) Remove the 2 pistons and compression spring.
(c) Remove the 2 wheel cylinder cups from each piston.
(d) Remove the bleeder plug cap and bleeder plug from the rear wheel brake cylinder assembly.

REASSEMBLY
1. INSTALL REAR WHEEL CYLINDER CUP KIT
(a) Temporarily tighten the bleeder plug to the wheel cylinder, and install the bleeder plug cap.

(b) Apply lithium soap base glycol grease to the 2 new wheel cylinder cups and the 2 pistons.
(c) Install the 2 wheel cylinder cups to each piston.
(d) Install the compression spring and 2 pistons to the rear wheel brake cylinder.
(e) Install the 2 new cylinder dust boots to the rear wheel brake cylinder.

2. INSTALL LH, FRONT OR UPPER REAR WHEEL BRAKE CYLINDER ASSEMBLY
(a) Install the rear wheel brake cylinder assembly with the 2 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
(b) Using SST, connect the brake tube.
SST 09023-00101
Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.)

3. APPLY HIGH TEMPERATURE GREASE
(a) Apply high temperature grease to the shoe attached surface of backing plate.
4. INSTALL REAR BRAKE SHOE
(a) Apply high temperature grease to the adjusting bolt.
(b) Install the rear brake strut set with the shoe return spring.

(c) Using a pliers, install the rear brake strut set, parking brake reaction lever and parking brake shoe lever LH with the 2 new C-washers.

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

(e) Using SST, install the rear brake shoe, pin, shoe hold down spring and shoe hold down spring cup.
SST 09718-00010
5. INSTALL FRONT BRAKE SHOE
(a) Install the rear brake automatic adjust lever LH, automatic adjust lever spring and parking brake shoe strut LWR to the front brake shoe.

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

(d) Using a needle-nose pliers, install the return spring.

(e) Using SST, install the shoe return spring to the front brake shoe.
SST 09921-00010
6. 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 that difference between the diameter is the correct shoe clearance.
Shoe clearance: 0.5 mm (0.020 inch)

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

7. INSTALL REAR BRAKE DRUM SUB-ASSEMBLY
8. ADJUST REAR DRUM BRAKE SHOE CLEARANCE
(a) Temporarily install the hub nuts.
(b) Remove the hole plug, and turn the adjuster and expand the shoe until the drum locks.

(c) Using a screwdriver, back off the adjuster 15 notches.
(d) Install the hole plug.
9. FILL RESERVOIR WITH BRAKE FLUID
10. BLEED BRAKE MASTER CYLINDER
11. BLEED BRAKE LINE
12. BLEED BRAKE ACTUATOR (w/ VSC)
13. CHECK FLUID LEVEL IN RESERVOIR
14. CHECK BRAKE FLUID LEAKAGE
15. INSTALL REAR WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
16. INSPECT PARKING BRAKE PEDAL TRAVEL
17. ADJUST PARKING BRAKE PEDAL TRAVEL