RearDrum Brake

Index/lnspection
Never use an air hose or dly brush to clean brake assemblies, Use an OSHA approved vacuum cleanarto avoid breathing brake dust, a Contaminatedbrake linings or drums reducestopping ability. a Block the tront wheels before iacking up ths rar of lhe vehicle.
'1.

Blockthe front wheels,loosenthe rear wheel nuts slightly,supportthe rear of the vehicleon safety stands,then removethe rearwheels. and removethe rearbrakedrum. Release the parkingbrake,

2.

I N m 10.9 kgtm, 6.5 lbf.ftl

WHEELCYLINDER Inspect for leakage. lf necessary, replace as an assembly.

PARKINGBRAKELEVER Markedleftand right.

u-cLrP
Replace.

WAVE WASHER

J
TENSIONPIN

@
PIVOTPIN

UPPER RETURN SPRING Check for weakness ano oamage,

10 mm BOLT 6,1Nm 15.5 kgf m, 47 tbf.ft)

/ f-l .^ *'t")

/
/

,.ro,".r r.*,"n
/ on , Installsecurely tensionpin.

PLATE BACKING lelt andrightMarked

ctEv'sB / ADJUSTER BOI-T

II

d " /
IU

(t
RETURN LOWER SPRING for weakness Check and oamage. SELF.ADJUSTER LEVEB SELF-ADJUSTER SPRING for weakness Check ano oamage.

ratchet Check teeth for wear and damage.

BRAKE SHOE Inspection, seepage19-36

lf brakeshoes are to be r e u s e d ,m a r k a n d r e a s s e m b l e in same position.

BRAKE DRUM Inspection, seepage'19 36

19-35

RearDrum Brake
Inspection
1 . Check the wheelcylinder for leakage. Checkthe brakeliningsfor cracking, glazing, wear, and contamination. Measure the brakeliningthickness. Brake Lining Thickness: Standard: 4.0 mm {0.157 in} ServiceLimit: 2.0 mm 10.08 in) 6. Measure the inside diameter oJ the brake drum usingthe insideverniercalipers. Drum Inside Diameter: - 200.0mm {7.870 - 7.874in) Standard: 199.9 Servic Limit: 201.0mm (7.913 inl
INSIDEVERNIER CALIPERS

WHEELCYLINDER

BRAKEORUM

LININGS

7.

l f t h e i n s i d ed i a m e t e ro f t h e b r a k ed r u m i s m o r e than the service limit, replace the brakedrum. C h e c kt h e b r a k ed r u m f o r s c o r i n g ,g r o o v e s ,a n d cracks.

8. NOTE; Measurement does not include brakeshoe thickness. 4. lf the brakelining thickness is lessthan the service limit, replace the brakeshoesas a set. Check the bearings in the hub unit for smooth operation. lf defective,refer to section 18

19-36

Brake ShoeDisassembly
1. Remove t h e t e n s i o np i n s b y p u s h i n gt h e r e t a i n e r springsand turningthem.
TENSION PINS

6.

Removethe wave washer,parkingbrakelever,and pivot pin from the brakeshoe by removingthe Uclrp.

PARKINGERAKE I-EVER

WAVE WASHER

@@
I U-CLIP
RETAINER SPRINGS Lower the brake shoe assembly,and remove the lower returnspring.
Replace.

BrakeShoeReassembly
- B020E) or 08733 1 . Apply brakecylindergrease(P/Nr equivalentrubber greaseto the sliding surfaceof the pivot pin,and insertthe pin into the brakeshoe. Installthe parkingbrakelever and wave washeron them with the U-clip, the pivot pin and secure NOTE: Pinchthe U-clip securelyto preventthe pivot pin from comingout of the brake shoe.

t
3. 4.

NOTEi Be carefulnot to damagethe dust cover on the wheelcylinder. the brakeshoeassembly. Remove the parkingbrakecablefrom the parking Disconnect brakelever. lever, Remove the upper returnspring,self-adjuster the brake a n d s e l f - a d j u s t es rp r i n g ,a n d s e p a r a t e snoe5.
ADJUSTEB BOLT Check ratchet teethfor wearano oamage. UPPER RETURN SPRING for weakness Check a n oo a m a g e .

,6;::"'
LEVER

N r
ll

//

,'/

(cont'd)

19-37

RearDrum Brake
BrakeShoeReassembly {cont'dl
C o n n e c tt h e p a r k i n g b r a k ec a b l e t o t h e p a r k i n g brakelever. Apply grease on eachslidingsurface. contaminated brake linings reduce !@ stopping ability. Keep greaseor oil off the blake linings. Wipe any excessgreaseoff the parts, . - 8020E) Apply brakecylindergrease{P/N:08733 o r e q u i v a l e nr t u b b e rg r e a s e t o t h e s l i d i n gs u r facesas shown. 6. Hook the self-adjusterspring to the self-adjuster leverfirst,then to the brakeshoe 7. Installthe clevisesand upper return spring. noting the installation direction. NOTE:Be carefulnot to damagethe wheel cylinder dustcovers, 8. Install the lower returnspring.
+a Slidingsurlace

5. Clean the threadedportionsof clevises A and B. Coat the threads of the cleviseswith grease.To shoften the clevises, tun the adjuster bolt.

9. Install the tensionpins and retaining springs.

SpRtNG uppERRETURT{

CLEVIS B
CLEVISA

Apply Molykote 44MAto the brakeshoeendsand opposite edgesofthe shoesas shown.

LOWER RETURN SPRING

_' o +O

Opposite edge of the shoe Brake shoe ends

't0. Installthebrakedrum.
1 1 . lf the wheel cylinderhas been removed,bleed the

brakesystem(seepage 19-7), and checkfor leaksat brakeline connections, and retighten if necessary. 12. Depressthe brake pedal severaltimes to set the self-adjusting brake. 1 3 . Adjustthe parkingbrake(seepage19-6).

19-38

Brake Hoses/Lines

Specifications Inspection/Torque
interference, and twisting. leaks, deterioration, t. Inspect the brakehosesfor damage, Also checkfor bent brakelines. rusting.and leakage. the brakelinesfor damage, 2. Check if necessary' and retighten for ieaksat hoseand line iointsand connections, 3. Check 4. Check the mastercylinderand ABS modulatorunit for damageand leakage tho brake hose clip whenevr the brake hose is serviced. CAUTION: Replace

l-lNE ABS MODULATOR UNIT-Io-BRAKE 19 N.m (1.9 kgf.m, 14lbl.ftl CONTROL VALVE. PROPOBTIONING io-BRAKELINE 11 tbf.ftl l5 N.m (1.5 LINE MASTER CYLINDER-Io-BMKE 11 lbf'ft) 15 N.m (1.5ksrf.m, REARDISGBRAKE: BRAKEHOSE-to4ALlPER {BANJOBOLT} 34 N.m (3.5kgtm,25 lbf ftl BLEEO SCREW 9 N'm (0.9kgf.m, 6.5 lM.ftl CYLINDER BRAKELINE-to-WHEEL 15 N.m (1.5kgl.m, 11 lbf.ftl SCREW BLEED 7 N.m {0.7kst m, 5 lbf,ttl

HOSE BRAKE LINE-io-aRAKE

15 N.m {1.5 11 tbtft)

HOSE BRAKELINE-Io-BRAKE 15 N.m (1.5kgt.m, 11 lbf'ft)

(BANJOBOLT} 3,1N.m 13.5 kgf.m, 25 lbf.ft)

19-39

BrakeHoses/Lines
HoseReplacement
CAUTION: . Bgfore reagsembling,chgck that all parts are free of dust and othor foroign particles. . Repl8ceparts with new ones whenever specified to do so, . Do not spill brake fluid on th6 vehicle; it may damage tho paint; if brake fluid does contact the paint, wash it off immediately with water. 1 . Replace the brakehose if the hose is twisted,cracked, or if it leaks. Disconnect the brakehosefrom the brakeline using a 10 mm flarenut wrench.
FLARE NUT WRENCH lCommercially available) BRAKELINE 6 mm HOSEBRACKET BOLTS 9.8 N.m {1.0kgf m, 7 lbtfr}

6. Installthe brakehose bracketand brakehose onto the knuckle first.then connect the brakehoseto the caliper with the banjobolt and new sealing washers.
BRAKEHOSE

BANJO BOI.T 34N.m {3.5kgf.m,25 lbt.ftl 7. Install t h e b r a k eh o s e o n t o t h e u o o e r b r a k eh o s e bracket with a new brakehoseclip
BRAKEHOSE 15 N.m (1.s ks{.m, 11 lbl.ftl

Removeand discardthe brake hose cliD from the brakehose.

8 . Connect the brakelineto the brakehose. After installing the brakehose,bleedthe brakesystem (seepage 19-7). Removethe banjo bolt, and disconnectthe brake hosefrom the caliper. Remove the brakehose bracket from the knuckle. .

1 0 . Perform the followingchecks:

. Check the brakehoseand line joint for leaks, and tightenif necessary. Checkthe brakehosesfor interference and twistIn g .

19-4 0

ParkingBrakeCable

and Replacement Inspection

CAUTION: The parking blake cables must not be bent or distorted. This will lead to stiff operation and premature cable failure.

PARKING BRAKE CABLE for faultymovement. Check PARKINGBRAKELEVER for smooth Check operation.

DISCBRAKETYPE: EOUALIZER CLEVIS PIN

\ i

PARKING BRAKESWITCH

Disc BrakeType: the parkingbrakecablefrom the leveron the Disconnect caliperby removingthe lockpin and clevispin, and remove the clip from the arm by removing the cable
PARKINGERAKECABLE

Drum BrakeType: Removethe parkingbrakecablefrom the backingplate usinga 12 mm offsetwrenchas shown.

PLATE BACKING

CLEVISPIN

{tt

12 mm WRENCH OFFSET (Commercially available)

19-41