Page 129 of 513

Removal
and
disassembly
The
single
master
cylinder
is
removed
and
disassembled
in
the
same
manner
as
the
tandem
type
master
cylinder
Inspection
Refer
to
the
section
covering
Inspection
of
tandem
type
master
cylinder
Reassembly
and
reinstallation
The
single
master
cylinder
is
reassembled
and
re
BRAKE
installed
in
the
same
manner
as
the
tandem
type
master
cylinder
BRAKE
LINE
The
bl1lke
pipe
adopts
a
double
wall
construction
steel
tubing
and
with
this
construction
lhe
rigidily
has
been
improved
Moreover
the
portion
of
brake
line
laid
beneath
the
vehicle
floor
is
galvanized
improving
the
corrosion
resistance
1
Bridge
tube
9
Brake
hose
2
Brake
tube
10
Bridge
tube
3
Brake
hose
11
Brake
tube
4
Brake
tube
12
Brake
hose
5
Brake
tube
13
Brake
tube
10
6
3
way
connector
14
3
way
connector
7
Brake
tube
15
Brake
tu
be
8
Brake
hose
Fig
BR
6
Brake
line
Removal
1
Remove
flare
nuts
from
both
ends
of
the
brake
tube
steel
tube
and
remove
clips
used
to
secure
the
brake
tube
on
the
paneL
The
brake
tube
can
be
removed
easily
I
1
I
Brake
master
cylinder
I
2
Front
3
way
connector
Fig
BR
7
Brake
tubes
around
master
cylinder
BR
5
Page 130 of 513

CHASSIS
1
I
Front
3
way
connector
I
2
I
Brake
master
cylinder
I
Fig
BR
8
Front
3
way
connector
2
The
brake
hose
rubber
hose
is
used
at
the
front
strut
assembly
unit
and
fear
axle
housing
unit
Remove
the
flare
nut
from
the
brake
tube
and
remove
the
hose
I
r
I
I
l
j
u
l
I
J
II
V
r
1
0
l
I
l
I
I
Brake
hose
I
3
I
Rear
axle
hOUSing
2
Rear
3
way
connector
Fig
BR
9
Brake
hose
and
3
way
connector
around
rear
ax
Ie
housi
g
1
1
Brake
hose
I
2
I
Strut
assembly
Fig
BR
J
0
Brake
hose
around
front
strut
assembly
Inspection
L
Thoroughly
clean
the
brake
tube
and
brake
hose
and
check
them
for
collapsing
crack
scar
and
rust
brake
tube
and
for
weakness
expansion
wear
etc
brake
hose
Replace
if
defective
2
Remove
mud
and
dust
from
the
brake
tube
clip
unit
and
check
the
clip
If
the
clip
covering
vinyl
coating
is
torn
repair
Reinstallation
1
Provide
a
sufficient
space
between
the
brake
lines
and
other
parts
so
that
the
brake
lines
are
not
interfered
with
other
parts
due
to
vibration
during
driving
SHORT
NAIL
DOUBLECLI
S
t
LONG
NAI
L
BRAKE
TUBE
PANEL
CLIP
COATED
WITH
VINYL
BRAKE
TUBE
Fig
BR
l1
Brake
tube
installation
clip
2
When
the
brake
hose
is
disconnected
from
the
3
way
connector
on
the
rear
axle
housing
once
be
sure
to
replace
the
copper
packing
with
a
new
one
3
Be
careful
not
to
warp
or
twist
the
brake
hose
and
particularly
be
careful
not
to
interfere
the
brake
hose
with
tires
and
suspension
components
4
Do
not
tighten
the
brake
line
installation
flare
nut
forcedly
or
excessively
BR
6
Page 131 of 513

Tightening
torque
3
way
connector
1
5
to
1
8
kg
m
10
8
to
13
0
ft
lh
1
5
to
1
8
kg
m
10
8
to
13
0
ft
lh
1
5
to
1
8
kg
m
10
8
to
13
0
ft
lb
0
7
to
0
9
kg
m
5
1
to
6
5
ft
1b
Master
cylinder
Brake
hose
Air
bleeder
5
Fill
the
master
cylinder
brake
fluid
reservoir
with
brake
fluid
and
perform
air
bleeding
complele1y
Note
a
Do
not
use
brake
fluid
other
than
specified
b
The
specified
brake
fluid
is
used
for
both
single
and
tandem
type
master
cylinders
6
Upon
completion
of
air
bleeding
make
sure
that
the
brake
operates
correctly
and
check
the
brake
tube
and
hose
connectors
for
fluid
leaking
Fully
depress
the
brake
pedal
continue
to
depress
the
brake
pedal
for
several
seconds
and
make
sure
that
no
brake
fluid
leaks
from
any
part
of
the
brake
line
Replace
defective
part
if
required
Brake
line
pressure
differential
warning
light
switch
A
warning
light
is
located
on
the
instrument
panel
to
warn
the
driver
when
a
pressure
difference
of
13
to
17
kg
cm2
185
to
2421bJsq
in
exists
between
the
front
and
rear
b
rake
systems
A
hydraulically
actuated
warning
light
switch
is
located
in
the
engine
compartment
Both
front
and
rear
brake
systems
are
connected
to
this
switch
assembly
When
a
pressure
difference
of
13
to
17
kgJcm2
185
to
242
lbJsq
in
occurs
between
the
front
and
rear
brake
systems
the
valves
will
shuttle
toward
the
side
with
the
low
pressure
The
valve
contacts
with
the
switch
terminal
BRAKE
the
ground
circuit
for
the
warning
light
is
completed
and
thus
the
warning
light
lights
In
this
case
correct
the
hydraulic
brake
problem
and
bleed
the
brakes
Check
the
warning
light
switch
assembly
for
a
proper
operation
Check
the
switch
assembly
for
fluid
leakage
Note
Do
not
attempt
to
repair
switch
for
any
reason
replace
switch
assembly
completely
1
To
front
brake
L
H
2
From
master
cylinder
F
3
From
master
cylinder
R
4
To
rear
brake
L
B
R
M
5
To
front
brake
R
H
Fig
BR
12
Warning
light
switch
r
I
@
I
I
3
I
Valve
assembly
4
Piston
load
spring
Wire
terminal
Brake
tube
Fig
BR
13
Sectional
view
of
warning
light
switch
BR
7
Page 132 of 513
CHASSIS
FRONT
DRUM
BRAKE
14
I
l
Fig
BR
14
Front
drum
brake
components
Removal
and
disassembly
Jack
up
the
vehicle
support
with
a
stand
and
remove
the
wheel
cover
and
tire
2
Remove
the
brake
drum
and
remove
the
hub
cap
and
hub
assembly
from
the
spindle
3
Disconnect
the
brake
tube
at
the
bracket
unit
of
the
strut
assembly
For
the
details
refer
to
Section
FA
R
W
i
1
t
V
t
1
1
d
j
2
rl
s
J
J
i
Z
j
Fig
BR
15
Front
drum
brake
4
Unhook
the
return
spring
and
remove
the
brake
shoe
assembly
5
Disconnect
the
bridge
tube
from
lhe
fore
and
after
wheel
cylinders
I
I
After
wheel
cylinder
Bridge
tube
I
3
I
Fore
wheel
cylinder
Fig
BR
16
Fore
and
after
wheel
cylinders
and
bridge
tube
6
Remove
the
installation
bolts
and
remove
the
fore
and
after
wheel
cylinders
BR
B
Page 133 of 513

7
Remove
the
brake
disc
installation
bolt
and
remove
the
brake
disc
from
the
spindle
8
Disassemble
the
wheel
cylinders
Inspection
l
Drums
If
they
show
score
excessive
out
of
round
and
so
forth
reconditioning
by
machining
is
required
Brake
drum
inner
diameter
203
2
mm
8
00
in
Drum
inside
out
of
roundness
Below
0
02
mm
0
0008
in
Max
allowable
drum
inner
diameter
204
5
mm
8
051
in
2
Linings
If
brake
shoe
linings
are
incomp1etedly
seated
soiled
or
greasy
or
deteriorated
due
to
excessive
heating
repair
or
replace
them
If
the
thickness
of
the
lining
is
less
than
1
5
mm
0
0591
in
replace
it
Note
a
If
oil
or
grease
is
found
on
linings
clean
thoroughly
with
carbon
tetrachloride
or
gasoline
b
After
installing
and
bonding
lining
grind
the
lining
face
to
a
diameter
equal
to
the
brake
drum
3
Check
the
adjusting
cams
for
their
smooth
operation
4
Return
springs
If
they
are
considerably
weak
replace
them
Return
spring
dimension
Wire
diameter
x
free
length
turns
3
2
x
118
mm
20
5
0
1260
x
4
65
in
20
5
Load
x
length
55
kg
I21
lb
x
127
1
mm
5
00
in
13
4
0
528
ilL
rnv
0
t
6
hl
03
118
4
65
FREE
LENGTH
UNIT
mm
in
Fig
BR
J
7
Return
spring
BRAKE
5
Check
the
brake
disc
for
distortion
6
Check
the
bore
of
the
wheel
cylinder
for
wear
sign
of
rust
and
damage
If
clearance
between
the
cylinder
and
the
piston
exceeds
0
15
mm
0
0059
in
replace
them
Fig
BR
J
8
Sectional
view
of
front
wheel
cylinder
7
When
the
wheel
cylinder
is
overhauled
it
is
recom
mended
that
cups
be
replaced
even
if
apparently
they
are
in
satisfactory
conditions
Cups
must
be
replaced
if
deformed
due
to
damage
crack
corrosion
smelling
andf
or
aging
Reassembly
and
reinstallation
The
rear
brake
is
reassembled
and
reinstalled
in
reverse
sequence
of
disassembly
and
removal
However
note
the
following
matters
When
assembling
the
wheel
cylinder
be
sure
to
apply
rubber
grease
to
the
piston
cup
and
other
rubber
parts
slightly
2
When
installing
the
wheel
cylinder
to
the
brake
disc
apply
brake
grease
to
the
cylinder
disc
and
adjusting
plate
sliding
surfaces
and
to
the
wheel
cylinder
lever
fulcrum
portion
sufficiently
so
that
the
wheel
cylinder
slides
smoothly
BR
9
Page 134 of 513
CHASSIS
Fig
BR
19
Greasing
points
on
brake
disc
3
Tighten
the
brake
disc
installation
bolt
to
2
7
to
3
7
kg
m
19
5
to
26
7
ft
lb
4
Adjust
brake
shoe
clearance
and
perform
air
bleeding
on
the
hydraulic
system
FRONT
DISC
BRAKE
Floating
type
disc
brake
Model
ANNET
12
14A
is
used
for
some
territories
as
a
standard
Rigidity
of
the
caliper
is
high
brake
pedal
feeling
is
adequate
and
the
pad
dragging
is
minimized
The
pad
is
returned
by
elasticity
of
the
piston
seal
When
the
pad
is
worn
the
piston
operating
stroke
increases
slipping
occurs
on
the
piston
seal
surface
and
thus
clearance
is
adjusted
automatically
Moreover
in
order
to
prevent
brake
squealing
a
shim
is
inserted
behind
the
pad
2
I
Clip
6
Brake
pad
II
Cylinder
block
2
Spring
7
Air
bleeder
12
Piston
A
3
Clevis
pin
8
Retaining
ring
13
Bias
spring
4
Shim
9
Boot
14
Yoke
spring
5
Hanger
spring
10
Piston
B
15
Yoke
Fig
BR
20
Front
disc
brake
components
BR
lO
Page 135 of 513

BRAKE
CYLINDER
SIDE
PISTON
SIDE
COMPR
ESSION
DECOMPRESSION
Movement
exceeding
the
elastic
displacement
is
released
with
slipping
on
the
seal
surface
Returns
in
elastic
displacement
of
the
seal
Fig
BR
21
Piston
seal
automatic
adjusting
operation
Brake
pad
Replacement
1
Jack
up
front
unit
of
the
vehicle
and
remove
lhe
front
wheeL
2
Remove
clip
from
the
retaining
pin
and
supporting
the
brake
pad
remove
the
retaining
pin
and
coil
spring
I
I
Brake
pad
2
Retaining
pin
I
31
Clip
Fig
BR
22
Removing
retaining
pin
3
Unhook
the
hanger
spring
and
withdraw
the
brake
pad
and
shim
with
a
pair
of
pliers
BR
ll
Fig
HR
2
Withdrawing
brake
pad
and
shim
Note
When
the
brake
pad
is
removed
do
not
depress
the
brake
pedal
or
otherwise
the
piston
will
come
out
Inspection
Clearance
between
the
brake
pad
and
rotor
is
adjusted
automatically
Check
the
brake
pad
for
wear
after
the
first
10
000
km
6
000
miles
driving
and
every
5
000
km
3
000
miles
thereafter
1
Clean
the
brake
pad
with
carbon
tetrachloride
or
gasoline
2
When
oil
and
or
grease
is
heavily
sticked
on
the
pad
or
when
deteriorated
or
deformed
due
to
overheating
replace
the
pad
with
a
new
one
3
When
thickness
of
the
friction
material
pad
is
less
than
1
6
mm
0
0630
in
replace
Replace
when
total
pad
thickness
is
less
than
6
1
mm
0
2402
in
Note
Replace
pads
as
a
set
Replacement
at
only
one
position
may
cause
uneven
brake
effect
It
is
recommended
that
rotation
of
pads
be
made
periodically
4
Check
the
rotor
Refer
to
Rotor
inspection
Reinstallation
1
Clean
the
calipers
and
piston
pad
installing
parts
Note
Do
not
use
mineral
oil
Be
careful
not
to
apply
oil
on
the
rotor
2
Depress
the
piston
into
the
cylinder
so
that
new
pad
can
be
installed
Page 136 of 513

CHASSIS
Fig
BR
24
Depression
piston
A
and
B
into
cylinder
Nota
a
Nota
that
brake
fluid
may
overflow
from
the
reservoir
It
is
recommeooed
that
operation
be
carried
out
by
loosening
the
breather
to
release
brake
fluid
b
The
piston
can
be
easily
pushed
in
by
hand
But
if
pushed
excessively
the
groove
of
piston
goes
inside
of
seal
as
shown
in
Figure
BR
25
and
the
seal
will
be
damaged
When
the
piston
is
pushed
excessively
into
the
cylinder
remove
the
brake
assembly
disassemble
it
push
out
the
piston
to
the
arrow
direction
as
shown
in
Figure
BR
25
and
reassemble
r
w
i
@
I
I
I
I
i
I
I
I
1
I
1
1
Piston
ieat
1
2
I
Normal
position
I
Fig
BR
25
Piston
pushing
in
position
3
Install
pad
and
anti
squeal
shim
assemble
the
anti
squeal
spring
and
retaining
pin
and
secure
them
with
clip
ARROW
MARK
Fig
BR
26
Arrow
mark
on
shim
I
Install
the
shim
so
that
the
arrow
mark
points
the
rotor
forward
rotating
direction
2
Apply
the
coil
spring
to
the
retaining
pin
which
is
distanced
from
the
air
bleeder
4
When
the
pad
is
installed
depress
the
brake
pedal
several
times
so
as
to
settle
down
the
pad
in
the
position
Caliper
assembly
Removal
L
Remove
the
brake
pad
Refer
to
Pad
re
placement
2
Disconnect
the
brake
tube
from
the
wheel
cylinder
3
Remove
the
strut
assembly
and
knuckie
arm
instal
lation
bolt
so
as
to
ease
removal
of
the
caliper
assembly
installation
bolt
BR
12