Page 889 of 2389
4. REMOVE PISTON FROM CYLINDER
(a) Put a piece of cloth or an equivalent as shown.
(b) Use compressed air to remove the piston from the
cylinder.
CAUTION: Do not place your fingers in front of the piston
when using compressed air.
3. REMOVE CYLINDER BOOT SET RING AND
CYLINDER BOOT
Using a screwdriver, remove the cylinder boot set ring and
cylinder boot.
DISASSEMBLY OF CYLINDER
(See page BR±34)
1. REMOVE SLIDING BUSHING AND DUST BOOTS
5. REMOVE PISTON SEAL FROM BRAKE CYLINDER
Using a screwdriver, remove the piston seal. 2. REMOVE MAIN PIN BOOT
Pull out the main pin boot.
± BRAKE SYSTEMRear BrakeBR±38
Page 890 of 2389

3. MEASURE ROTOR DISC RUNOUT
Measure the rotor disc runout at 10 mm (0.39 in.) from the
outer edge of the rotor disc.
Maximum. disc runout: 0.15 mm (0.0059 in.)
If the runout is greater than the maximum, replace the
disc.
HINT: Before measuring the runout, confirm that the hub
bearing play is within speification.
4. IF NECESSARY, REPLACE ROTOR DISC
(a) Remove the axle carrier mounting bolt and nut of up-
per side.
(b) Remove the torque plate.
(e) Remove the hub nuts of the temporarily installed disc
and pull off the rotor disc.
(d) Install a new rotor disc and loosely install the hub
nuts.
INSPECTION AND REPAIR OF REAR
BRAKE COMPONENTS
1. MEASURE PAD LINING THICKNESS
Standard thickness: 10.0 mm (0.394 in.)
Minimum thickness: 1.0 mm (0.039 in.)
Replace the pad if the thickness is less than the minimum
or if it shows sign of uneven wear.
2. MEASURE ROTOR DISC THICKNESS
Standard thickness: 10.0 mm (0.394 in.)
Minimum thickness: 9.0 mm (0.354 in.)
If the disc is scored or worn, or if thickness is less than
minimum, repair or replace the disc.
(e) Install the torque plate and tighten the mounting bolt.
Torque: 475 kg±cm (34 ft±lb, 47 N±m)
(f) Install the axle carrier mounting bolt and nut of upper
side.
Torque: 2,600 kg±cm (188 ft±lb, 255 N±m)
± BRAKE SYSTEMRear BrakeBR±39
Page 891 of 2389
ASSEMBLY OF CYLINDER
(See page BR±34)
1. APPLY LITHIUM SOAP BASE GLYCOL GREASE TO
FOLLOWING PARTS:
(a) Main pin boot
(b) Sliding bushing and dust boots
(e) Piston, piston seal and cylinder boot
5. INSTALL SLIDING BUSHING AND DUST BOOTS
(a) Install the sliding bushing and dust boots into the
brake cylinder.
(b) Insure that the boots are secured firmly to the brake
cylinder groove. 3. INSTALL CYLINDER BOOT AND SET RING IN
CYLINDER
4. INSTALL MAIN PIN BOOT
Install the main pin boot in place. 2. INSTALL PISTON SEAL AND PISTON IN CYLINDER
± BRAKE SYSTEMRear BrakeBR±40
Page 892 of 2389
INSTALLATION OF CYLINDER
(See page BR±34)
1. INSTALL PADS
(See steps 7 and 8 on pages BR±35 and 36)
2. INSTALL CYLINDER
(See step 9 on page BR±36)
4. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND
BLEED BRAKE SYSTEM
(See page BR±7)
5. CHECK FOR LEAKS3. INSTALL FLEXIBLE HOSE TO BRAKE CYLINDER
Set the flexible hose and new gaskets in position and
install the union bolt and torque it.
Torque: 310 kg±cm (22 ft±ib, 30 N±m)
± BRAKE SYSTEMRear BrakeBR±41
Page 893 of 2389
Parking Brake
(For Rear Disc Brake)
COMPONENTS
2WD (w/o A.B.S.) and 4WD
2WD (w/ A.B.S.)
± BRAKE SYSTEMRear BrakeBR±42
Page 894 of 2389
DISASSEMBLY OF PARKING BRAKE
1. REMOVE REAR DISC BRAKE ASSEMBLY
(a) Remove the axle carrier mounting bolt and nut of up-
per side.
(b) Remove the two mounting bolts and remove the disc
brake assembly.
(c) Suspend the disc brake so the hose is not stretched.
4. REMOVE FRONT SHOE, ADJUSTER AND TENSION
SPRING
(a) Slide out the front shoe and remove the shoe adjust-
er.
(b) Remove the shoe strut with spring.
(c) Disconnect the tension spring and remove the front
shoe. 3. REMOVE SHOE RETURN SPRINGS
[2WD (w/o A.B.S.) and 4WD]
Using SST, remove the shoe return springs.
SST 09717±20010 2. REMOVE ROTOR DISC
HINT: If the rotor disc cannot be removed easily, return the
shoe adjuster until the wheel turns freely.
[2WD (w/ A.B.S.)]
Using needle±nose pliers, remove the shoe return springs.
± BRAKE SYSTEMRear BrakeBR±43
Page 895 of 2389

5. REMOVE REAR SHOE
(a) Slide out the rear shoe.
(b) Remove the tension spring from the rear shoe.
(c) Disconnect the parking brake cable from the parking
brake shoe lever.
(d) Remove the shoe hold±down spring cups, springs
and pins.
2. MEASURE BRAKE SHOE LINING THICKNESS
Standard thickness: 2.0 mm (0.079 in.)
Minimum thickness: 1.0 mm (0.039 in.)
If the shoe lining is less than minimum or shows signs of
uneven wear, replace the parking brake shoes.
3. MEASURE BRAKE DISC INSIDE DIAMETER
Standard inside diameter: 170 mm (6.69 in.)
Maximum inside diameter: 171 mm (6.73 in.)
If the disc is scored or worn, the brake disc may be lathed
to the maximum inside diameter.
4. INSPECT PARKING BRAKE LINING AND DISC FOR
PROPER CONTACT
If the contact between the brake lining and disc is improp-
er, repair the lining with a brake shoe grinder, or replace
the brake shoe assembly.
INSPECTION AND REPAIR OF
PARKING BRAKE COMPONENTS
1. INSPECT DISASSEMBLED PARTS
Inspect the disassembled parts for wear, rust or damage.
± BRAKE SYSTEMRear BrakeBR±44
Page 896 of 2389
5. MEASURE CLEARANCE BETWEEN PARKING BRAKE
SHOE AND LEVER
Using a feeler gauge, measure the clearance.
Standard clearance: Less than 0.35 rnm (0.0138 in.)
If the clearance is not within specification, replace the
shim with one of the correct size.
6. IF NECESSARY, REPLACE SHIM
(a) Remove the parking brake lever, and install the cor-
rect size shim. .
(b) Install the parking brake lever with a new C±washer.
(c) Remeasure the clearance.
± BRAKE SYSTEMRear BrakeBR±45