REAR BRAKE INSTALLATION


  1. TEMPORARILY TIGHTEN REAR DRUM BRAKE BLEEDER PLUG

  2. INSTALL REAR WHEEL BRAKE CYLINDER CUP KIT


    1. Apply the lithium soap base glycol grease to 2 new wheel cylinder cups and 2 pistons.

    2. Install the 2 wheel cylinder cups on each piston.

    3. Install the compression spring and the 2 pistons to the wheel brake cylinder assembly.

    4. Install the 2 new cylinder dust boots to the wheel brake cylinder assembly.

  3. INSTALL REAR WHEEL BRAKE CYLINDER ASSEMBLY


    1. A003EFL

      Install the wheel brake cylinder assembly with the 2 bolts.

      Torque:
      9.5 N*m  { 97 kgf*cm, 84 in.*lbf }

    2. Using a union nut wrench, connect the brake tube.

      Torque:
      15 N*m  { 155 kgf*cm, 11 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

  4. APPLY HIGH TEMPERATURE GREASE


    1. A003FL6E02
      Text in Illustration
      *1 High temperature grease

      Apply high temperature grease to the shoe attached surface of the backing plate.

  5. INSTALL PARKING BRAKE SHOE STRUT SET


    1. A003C9VE03
      Text in Illustration
      *1 High temperature grease

      Apply the high temperature grease to the adjusting bolt.

    2. Install the tension spring to the shoe strut set.

  6. INSTALL REAR BRAKE SHOE


    1. for 254 mm drum:


      1. A003IDME02
        Text in Illustration
        *1 Brake Shoe Lever
        *2 Brake Shoe Strut Set
        *3 Rear Brake Shoe
        *4 Rear Cushion Lever
        *5 C-washer

        Using pliers, install the rear brake shoe, shoe strut set, rear cushion lever and shoe lever with a new C-washer.

      2. A003EMZ

        Connect the parking brake cable No. 3 to the front brake shoe.

      3. A003D7FE01

        Using SST, install the rear brake shoe, pin, shoe hold down spring and shoe hold down cup.

        SST
        09718-00011

    2. for 295 mm drum:


      1. A003GO0E01
        Text in Illustration
        *1 Rear Brake Shoe
        *2 Brake Shoe Strut Set
        *3 Brake Shoe Lever
        *4 Automatic Adjust Lever
        *5 C-washer
        *6 E-ring

        Install the rear brake shoe, brake shoe strut set and shoe lever with a new C-washer.

      2. Install a new E-ring and the automatic adjust lever.

      3. A003AYI

        Connect the parking brake cable No. 3 to the front brake shoe.

      4. A003DHG

        Install the tension spring as shown in the illustration.

      5. A003GYTE01

        Using SST, install the rear brake shoe, pin, shoe hold down spring and shoe hold down cup.

        SST
        09718-00011

  7. INSTALL FRONT BRAKE SHOE


    1. for 254 mm drum:


      1. Install the return spring to each brake shoe.

      2. A003FXUE01

        Using SST, install the front brake shoe, pin, shoe hold down spring and shoe hold down cup.

        SST
        09718-00011
      3. A003AX0E02
        Text in Illustration
        *A LH Side
        *B RH Side

        Install the brake shoe lower strut.

        Note

        Make sure that the shoe lower strut and brake rear cushion lever are securely engaged.

      4. A003D9P

        Using needle-nose pliers, install the tension spring.

    2. for 295 mm drum:


      1. A003CTHE01

        Using SST, install the front brake shoe, pin, shoe hold down spring and shoe hold down cup.

        SST
        09718-00011

      2. Install the return spring to each brake shoe.

  8. CONNECT PARKING BRAKE SHOE STRUT SET


    1. for 254 mm drum:


      1. A003B1LE01

        Using SST, install the upper side tension spring.

        SST
        09703-30011

    2. for 295 mm drum:


      1. A003CWOE01

        Using SST, install the upper side tension spring.

        SST
        09703-30011

  9. INSTALL AUTOMATIC ADJUST LEVER


    1. for 254 mm drum:


      1. A003CMW

        Install the automatic adjust lever and tension spring.

        Note

        Make sure to install the automatic adjust lever between the groove of the shoe strut set and brake shoe.

  10. INSPECT REAR DRUM BRAKE


    1. Check the each part is installed properly.

      A003E68E02
      A003IDGE01
      Text in Illustration
      *A for 254 mm Drum *B for 295 mm Drum
      *C LH Side *D RH Side
      *a Front - -

      Note

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

    2. If they are not installed correctly, reinstall them as shown in the illustration.

  11. INSTALL REAR AXLE BRAKE DRUM GASKET


    1. Install the new brake drum gasket to the rear axle shaft.

  12. INSTALL REAR BRAKE DRUM SUB-ASSEMBLY

  13. ADJUST REAR DRUM BRAKE SHOE CLEARANCE


    1. Using a screwdriver from a service hole, turn the adjuster to expand the shoes so that the brake shoes touch the brake drum.

      A003HG5E01
      Text in Illustration
      *A for 295 mm Drum *B for 254 mm Drum

    2. Using another screwdriver, push up the automatic adjust lever and turn the adjuster to contract the shoes so that the brake shoe does not touch the brake drum. Then turn the adjuster another 180 degrees to further contract the shoes.

      A003HEME01
      Text in Illustration
      *A for 295 mm Drum *B for 254 mm Drum

    3. Install the hole plug.

  14. ADD BRAKE FLUID

    Fluid
    SAE J1703 or FMVSS No. 116 DOT3 or equivalent

  15. BLEED BRAKE LINE


    1. Connect the vinyl tube to the bleeder plug.

    2. Depress the brake pedal several times and loosen the bleeder plug with the pedal held down.

    3. At the point where the fluid stops coming out, tighten the bleeder plug and release the brake pedal.

    4. Repeat this procedure until the air in the brake fluid is completely bled out.

    5. Tighten the bleeder plug.


      1. Front bleeder plug:

        Torque:
        10.8 N*m  { 110 kgf*cm, 8 ft.*lbf }

      2. Rear bleeder plug:

        Torque:
        11.0 N*m  { 112 kgf*cm, 8 ft.*lbf }

    6. Repeat the above procedure to bleed the air out of the brake line for each wheel.

  16. INSPECT BRAKE FLUID LEVEL


    1. Check the fluid level and add fluid if necessary.

      Fluid
      SAE J1703 or FMVSS No.116 DOT3 or equivalent

  17. INSTALL REAR WHEEL

    Torque:
    100 N*m  { 1020 kgf*cm, 74 ft.*lbf }

  18. INSPECT PARKING BRAKE CONTROL HANDLE TRAVEL


    1. Pull firmly on the parking brake control handle.

    2. Release the parking brake lock, and return the parking brake control handle to its off position.

    3. Slowly pull the parking brake control handle all the way up, and count the number of clicks.

      Parking brake control handle travel
      10 to 16 clicks at 200 N (20 kgf, 44 lbf) (except Super Long Wheelbase)
      12 to 18 clicks at 200 N (20 kgf, 44 lbf) (for Super Long Wheelbase)

      Tech Tips


      • If the number of clicks falls outside of the specified range, release the parking brake lock and adjust it.

      • If there are fewer clicks than the specified value, loosen the parking brake wire adjustment nut an the lock nut. With the parking brake cable loosened, adjust the clearance between the brake drum and lining.

  19. ADJUST PARKING BRAKE CONTROL HANDLE TRAVEL


    1. Lift the vehicle

    2. A003F46E01

      Depress the parking brake handle. Hold the parking brake adjusting nut using a wrench, and loosen the lock nut.

    3. Turn the parking brake adjusting nut until the parking brake handle travel meets the above specification.

      Parking brake control handle travel
      10 to 16 clicks at 200 N (20 kgf, 44 lbf) (except Super Long Wheelbase)
      12 to 18 clicks at 200 N (20 kgf, 44 lbf) (for Super Long Wheelbase)

    4. Count the number of clicks after depressing and releasing the parking brake control handle 3 or 4 times.

    5. Check whether the parking brake drags or not.

    6. When operating the parking brake control handle, check that the parking brake indicator light comes on.

      Standard
      Brake warning light always comes on at the first click.

    7. Hold the parking brake adjusting nut using a wrench, and tighten the lock nut.

      Torque:
      14.5 N*m  { 148 kgf*cm, 11 ft.*lbf }

    8. Lower the vehicle.