Page 137 of 513

BRAKE
Fig
BR
27
Removing
strut
assembly
and
knuckle
arm
installation
bolt
4
Remove
the
caliper
assembly
installation
bolt
and
separate
it
from
the
strut
assembly
Fig
BR
28
Removing
caliper
assembly
instaUation
bolt
Disassembly
I
Remove
mud
and
other
contaminations
from
the
caliper
assembly
before
disassembly
2
Drain
brake
fluid
from
the
wheel
cylinder
3
Loosen
the
air
bleeder
and
depress
tha
pistons
A
and
B
into
the
cylinder
Refer
to
Pad
replacement
4
Secure
the
yoke
in
a
vise
and
tap
the
yoke
head
with
a
hammer
The
cylinder
body
can
then
be
removed
from
the
yoke
When
removing
the
cylinder
body
be
careful
not
to
allow
the
piston
A
coming
out
from
the
cylinder
BR
13
i
c
J
l
l
7
I
0
I
I
i
I
f
1
1
J
t
1
Fig
BR
29
Tapping
yoke
head
5
Remove
the
bias
ring
from
the
piston
A
6
Remove
the
retaining
rings
and
boots
from
the
pistons
A
and
B
J
l
lj
7
fI
II
l
j
B
11
I
Retaining
ring
121
Boot
Fig
BR
30
Cylinder
body
and
piston
7
Depress
and
remove
the
piston
from
the
cylinder
8
Remove
the
pislon
seal
from
the
cylinder
Note
Remove
the
piston
seal
carefully
with
fingers
so
that
the
cylinder
wall
is
not
damaged
9
Remove
the
yoke
spring
and
yoke
bias
spring
from
the
yoke
Inspection
and
repair
Thoroughly
clean
all
disassembled
parIs
and
check
them
for
the
following
items
Page 138 of 513

CHASSIS
Note
When
cleaning
rubber
parts
use
alcohol
or
brake
fluid
If
rubber
parts
are
cleaned
with
mineral
oil
they
will
be
deteriorated
1
Calipers
If
the
cylinder
wall
is
damaged
or
worn
replace
If
the
cylinder
wall
is
rusted
or
foreign
matters
are
accumu
lated
on
the
cylinder
wall
carefully
polish
with
fine
emery
paper
so
that
the
cylinder
wall
is
not
damaged
If
rusted
or
roughened
excessively
replace
2
Pad
See
paragraph
covering
replacement
of
pad
3
Piston
Replace
if
unevenly
worn
damaged
and
or
rusted
Note
The
piston
sliding
surface
is
plated
Thus
do
not
use
emery
paper
although
rusted
or
foreign
matters
are
Slicked
on
the
sliding
surface
4
Seals
Primarily
replace
both
piston
and
dust
seals
whenever
overhauling
Note
The
piston
seal
affects
not
only
leaking
but
also
piston
return
For
this
reason
replace
the
piston
seal
even
if
the
damage
is
minor
S
Rotor
Check
the
rotor
and
if
it
shows
score
excessively
out
of
round
and
so
forth
reconditioning
by
machining
is
required
If
any
abnormal
conditions
such
as
crack
distortion
and
excessive
deflection
replace
the
rotor
Standard
rotor
thickness
9
5
mm
0
3740
in
Limit
of
reconditionillg
rotor
in
thkkn
8
4
mm
0
3307
in
Deflection
of
the
rotor
Below
0
03
mm
0
0012
in
I
I
I
I
ri
U
h
J
r
Fig
BR
1
Measuring
deflection
of
disc
Reassembly
Apply
the
rubber
grease
to
cylinder
bore
and
install
the
piston
seal
2
Insert
the
bias
ring
to
piston
A
so
that
the
roundish
portion
of
bias
ring
comes
to
the
bottom
of
piston
1
ilY
f@
I
I
C
I
1
n
tL
c
ffi
1
1
fJ
u
IZ
@
I
I
Yoke
Chamfer
13
PistonA
I
4
Roundish
portion
Fig
BR
32
Installing
bias
ring
into
piston
A
Note
Be
careful
not
to
confuse
the
piston
A
with
B
BR
14
Page 139 of 513
BRAKE
i
f
F
PISTON
A
PISTON
S
Fig
BR
33
Piston
A
and
B
3
Apply
rubber
grease
lightly
to
the
sliding
portion
of
piston
and
insert
the
piston
into
the
cylinder
Note
When
inserting
the
piston
be
careful
not
to
insert
too
far
4
1
nstaU
the
boot
and
retaining
ring
Fig
BR
34
Installing
boot
5
Install
so
that
the
yoke
groove
of
bias
ring
of
piston
A
coincides
with
the
yoke
groove
of
cylinder
6
Install
so
that
the
projected
portion
of
yoke
spring
faces
to
disc
as
shown
in
Figures
BR
35
and
36
BR
15
YOKE
SPRING
Fig
BR
35
Installation
of
yoke
spring
1
Fig
BR
36
Installation
of
yoke
spring
2
7
Install
the
bias
spring
to
yoke
so
that
the
bias
spring
comes
to
the
air
bleeder
side
of
cylinder
8
Apply
the
brake
grease
to
the
yoke
sliding
portion
of
cylinder
9
With
the
yoke
spring
inserted
to
cylinder
groove
lightly
correct
position
of
the
bias
spring
so
that
the
groove
of
bias
spring
conincides
with
yoke
Page 140 of 513
CHASSIS
Fig
BR
37
Correcting
bias
spring
position
10
Assemble
the
cylinder
body
and
yoke
by
tapping
the
yoke
lightly
11
Apply
the
brake
grease
fully
to
the
yoke
sliding
groove
of
cylinder
12
Install
the
air
bleeder
Reinstallation
Reinstall
the
caliper
assembly
in
reverse
sequence
of
removal
After
the
pad
is
installed
completely
bleed
the
REAR
BRAKE
r
e
hydraulic
line
and
measure
the
rotation
torque
of
disc
Fig
BR
38
Measuring
starting
torque
Starting
torque
9
0
kg
cm
7
80
in
lb
At
the
hub
bolt
1
57
kg
3
45
lb
Tightening
torque
Caliper
assembly
installation
bolt
4
6
to
6
kg
m
33
3
to
44
1
ft
lb
Brake
tube
flare
nut
connected
to
wheel
cylinder
1
5
to
1
8
kg
m
10
8
to
3
0
ft
lb
JJ
i
o
C
EID
I
o
fj
t
Fig
BR
39
Rear
brake
construction
BR
16
Page 141 of 513

BRAKE
Removal
and
disassembly
1
Jack
up
the
rear
side
of
the
vehicle
support
with
a
stand
and
remove
the
wheeL
2
Loosen
the
hand
brake
wire
remove
the
clevis
pin
from
the
rear
wheel
cylinder
lever
and
disconnect
the
hand
brake
wire
Remove
the
return
spring
pull
spring
I
I
k
re
I
I
l
nlinder
lever
I
Fig
BR
40
Removing
hand
brake
wire
3
Remove
the
brake
drum
Remove
the
shoe
retainer
and
return
spring
and
remove
the
brake
shoe
assembly
I
I
I
I
Brake
shoes
Shoe
retainer
Return
spring
Adjuster
Fig
BR
41
Rear
drum
brake
4
Disconnect
the
brake
tube
from
the
wheel
cylinder
5
Remove
the
dust
cover
adjusting
shims
and
plates
The
wheel
cylinder
can
then
be
removed
easily
6
Remove
the
adjuster
assembly
7
Remove
the
flange
bolt
from
the
rear
axle
housing
remove
the
rear
axle
shaft
The
brake
disc
can
then
be
removed
together
with
the
rear
axie
shaft
Refer
to
Section
RA
Fig
BR
42
Removing
brake
disc
Inspection
For
the
rear
brake
inspection
the
instructions
for
front
drum
brake
apply
Return
spring
dimensions
Wire
dia
x
free
length
active
turns
Load
x
length
Cylinder
side
2
0
x
119
2
mm
28
0
0787
x
4
69
in
28
10
6
kg
x
132
7
mm
33
4lb
x
5
22
in
Adjuster
side
2
0
x
69
5
mm
20
0
0787
x
2
736
in
20
8
6
kg
x
76
7
mm
I9
6lb
d
020
in
CYLINDER
SIDE
t
2
0
472
r
lif
r
1
5
58
2
283F
119
2
4
69
FREE
LENGTH
ADJUSTER
SIDE
1210
472
11
0
433
J54J
69
5
2
736
FREE
LENGTH
UNIT
mm
in
Fig
BR
43
BR
17
Page 142 of 513
CHASSIS
Reassembly
and
reinstallation
Reassemble
and
reinstall
the
rear
brake
in
reverse
sequence
of
disassembly
and
removal
nuting
the
follow
ing
matters
When
reassembling
refer
to
the
notes
for
front
drum
brake
1
Measure
the
wheel
cylinder
sliding
resistance
with
the
brake
tube
disconnected
as
shown
in
Figure
BRM
and
make
sure
that
the
sliding
resistance
is
in
range
from
2
to
7
kg
4
409
to
15
432Ib
Note
When
sliding
is
improper
the
brake
shoe
does
not
return
smoothly
2
Tighten
the
brake
disc
installation
bolt
flange
bolt
1
5
to
2
0
kg
m
10
8
to
14
5
ft
lb
3
Tighten
the
adjuster
assembly
installation
bolt
1
6
to
2
2
kg
m
11
6
to
15
9
ft
lb
HAND
BRAKE
4
j
1
I
1
I
Spring
balancer
I
2
I
Wheel
cylinder
Fig
BR
44
Measuring
sliding
resistance
1
Hand
brak
e
lever
2
Cable
3
Clip
4
Lock
plate
5
Tu
m
buckle
Hand
brake
adjuster
6
Cable
7
Cable
8
Hanger
strap
9
Return
spring
10
Cable
shank
11
Hand
brake
lever
cover
Fig
BR
45
Hand
brake
construction
BR
1B
Page 143 of 513

Removal
Loosen
the
turn
buckle
adjusting
nut
and
separate
the
front
cable
from
the
rear
cable
1
Rear
cable
2
Turn
buckle
3
Lock
nut
4
Front
cable
5
Propeller
shaft
Fig
BR
46
Removing
turn
buckle
2
Remove
the
lock
plate
located
immediately
in
front
of
the
turn
buckle
remove
the
clip
in
the
passenger
compartment
side
and
disconnect
the
front
cable
3
Remove
the
hand
brake
lever
cover
Remove
the
lever
assembly
with
the
front
cable
connected
toward
the
passenger
compartment
side
1
I
Front
cable
2
Cover
I
3
Hand
brake
lever
Fig
BR
47
Removing
hand
brake
lever
4
Remove
the
hanger
strap
installation
bolt
withdraw
the
lock
plate
from
the
axle
housing
brncket
unit
and
disconnect
the
rear
cable
BRAKE
I
1
I
Hanger
strap
installation
bolt
r
2
I
Lock
plate
Fig
BR
48
Disconnecting
Tear
cable
from
rear
axle
housing
5
Loosen
the
hanger
slrap
unit
nut
and
separate
the
parts
into
nut
hanger
strap
washer
and
bracket
Discon
nect
the
wheel
cylinder
lever
side
brake
cable
r
v
I
j
1
r
1fil
lt
J
l
1
1
I
c
2
1
Dust
cover
2
Hanger
strap
washer
3
Bracket
4
Hanger
strap
5
Hanger
strap
instal
lation
bolt
Fig
BR
49
Hanger
strap
mounted
on
rear
axle
housing
Note
Do
not
remove
the
dust
cover
from
the
cable
but
leave
it
installed
on
the
cable
Inspection
Check
the
cable
for
damage
and
other
defective
conditions
and
replace
if
required
2
Replace
if
sliding
part
is
worn
excessively
3
Make
sure
that
the
hand
brake
lever
can
be
operated
smoothly
and
that
the
ratchet
pawl
and
teeth
are
not
wom
unusually
or
damaged
BR
19
Page 144 of 513

CHASSIS
4
With
the
hand
brake
lever
pulled
depress
the
push
button
and
make
sure
that
the
pawl
disengages
the
teeth
when
the
push
button
is
depressed
5
to
6
mm
0
1969
to
0
2362
in
completely
5
Make
sure
that
the
cable
dust
cover
is
not
damaged
or
warped
Reinstallation
Reinstall
the
hand
brake
in
reverse
sequence
of
removal
noting
the
following
matters
Be
careful
not
to
damage
or
twist
the
dust
cover
2
Tighten
the
hanger
strap
and
the
cable
connecting
nut
to
0
8
to
1
0
kg
m
5
8
to
7
2
ft
1b
3
When
adjusting
rear
brake
shoe
clearance
be
sure
to
loosen
the
inner
cable
sufficiently
4
Grease
the
sliding
parts
with
multi
purpose
grease
MIL
G
2108
or
G
10924
AD
JUSTMENT
Brake
shoe
clearance
Front
drum
brake
Jack
up
the
vehicle
and
remove
the
wheeL
2
With
the
brake
drum
installed
tighten
the
cam
adjusting
stud
clockwise
up
to
such
an
extent
that
the
brake
shoe
comes
into
contact
with
the
brake
drum
by
applying
your
hand
and
tool
from
reverse
side
of
the
brake
disc
Fig
BR
50
Adjusting
front
brake
shoe
clearance
Turn
the
cam
adjusting
5
ud
counterclockwise
up
to
such
an
extent
that
the
brake
shoe
is
separated
slightly
from
the
brake
drum
4
Turn
the
brake
drum
and
if
the
brake
shoe
interferes
the
brake
drum
readjust
the
clearance
In
addition
depress
the
brake
pedal
and
make
sure
that
the
brake
operates
effectively
and
correctly
Front
disc
brake
Ordinarily
adjustment
is
not
required
because
clear
ance
between
pad
and
rotor
is
adjusted
automatically
by
elasticity
of
the
piston
seal
Rear
brake
Jack
up
the
vehicle
and
remove
the
wheeL
2
Appiying
your
hand
and
tool
from
reverse
side
of
the
brake
disc
tighten
the
brake
adjuster
wedge
clockwise
up
to
such
an
extent
that
the
brake
shoe
comes
into
contact
with
the
brake
drum
Fig
BR
51
Adjusting
rear
brake
shoe
clearance
3
Return
the
adjuster
wedge
properly
so
that
the
brake
shoe
is
separated
from
the
brake
drum
slightly
4
Turn
the
brake
drum
and
if
the
brake
shoe
interferes
the
brake
drum
readjust
In
addition
de
press
the
brake
pedal
and
make
sure
that
the
brake
operates
effectively
and
correctly
BR
20