Page 1009 of 4087
3. REMOVE FOLLOWING PARTS:
(a) 2 anti±squeal springs
(b) 2 brake pads
CALIPER DISASSEMBLY
BR0EP±04
1. REMOVE CYLINDER BOOT SET RING AND CYLINDERBOOT
Using a screwdriver, remove the cylinder boot set ring and
cylinder boot from the caliper.
2. REMOVE PISTON
(a) Place a piece of cloth or similar article between the piston and
the caliper.
(b) Use compressed air to remove the piston from the caliper.
CAUTION: Do not place your fingers in front of the piston when
using compressed air.
3. REMOVE PISTON SEAL Using a screwdriver, remove the piston seal from the caliper.
4. REMOVE SLIDING PINS AND DUST BOOTS
(a) Remove the 2 sliding pins from the torque plate.
BR±40
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BRAKE SYSTEM REAR BRAKE (Disc Brake)
WhereEverybodyKnowsYourName
Page 1010 of 4087

(b) Using a screwdriver and hammer, tap out the 2 dust boots.
REAR BRAKE COMPONENTS
INSPECTION AND REPAIR
BR04B±06
1. MEASURE PAD LINING THICKNESSUsing a ruler, measure the pad lining thickness.
Standard thickness:
10.0 mm (0.394 in.)
Minimum thickness: 1.0 mm (0.039 in.)
Replace the pad if the pad's thickness is at the minimum
thickness or less, or if the pad has severely uneven wear.
2. MEASURE DISC THICKNESS
Using a micrometer, measure the disc thickness.
Standard thickness:
16.0 mm (0.630 in.)
Minimum thickness:
15.0 mm (0.591 in.)
Replace the disc if the thickness of the disc is at the minimum
thickness or less. Replace the disc or grind it on a lathe if it
is scored or is worn unevenly.
3. MEASURE DISC RUNOUT
Measure the disc runout at 10 mm (0.39 in.) from the outer
edge of the disc.
Maximum disc runout:
0.05 mm (0.0020 in.)
If the disc's runout is at the maximum value or greater, check
the bearing play in the axial direction and check the axle hub
runout (See page SA±52). If the bearing play and axle hub
runout are not abnormal, adjust the disc runout.
4. IF NECESSARY, ADJUST DISC RUNOUT
(a) Remove the 2 bolt and torque plate from the carrier.
(b) Remove the hub nuts and the disc. Reinstall the disc 1/5 of
a turn round from its original position on the hub. Install and
torque the hub nuts.
Torque: 103 N Vm (1,050 kgf Vcm, 76 ft Vlbf)
Remeasure the disc runout. Make a note of the runout and
the disc's position on the hub.
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BRAKE SYSTEM REAR BRAKE (Disc Brake)BR±41
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Page 1011 of 4087
(c) Repeat (b) until the disc has been installed on the 3remaining hub positions.
(d) If the minimum runout recorded in (b) and (c) is less than 0.05
mm (0.0020 in.), install the disc in that position.
(e) If the minimum runout recorded in (b) and (c) is greater than 0.05 mm (0.0020 in.), replace the disc and repeat step 3.
(f) Install the torque plate and tighten the 2 bolts.
Torque: 104 N Vm (1,065 kgf Vcm, 77 ft Vlbf)
CALIPER ASSEMBLY
BR0EQ±04
1. APPLY LITHIUM SOAP BASE GLYCOL GREASE TO
PARTS INDICATED WITH ARROWS
2. INSTALL DUST BOOTS AND SLIDING PINS
(a) Using a 19 mm socket and hammer, tap in 2 new dust boots into the torque plate.
(b) Confirm that the metal plate portion of the dust boot fits snugly in the torque plate.
(c) Insert 2 sliding pins into the torque plate.
NOTICE: Insert the sliding pin with the sliding bushing into the
bottom side.
BR±42±
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WhereEverybodyKnowsYourName
Page 1012 of 4087
3. INSTALL PISTON SEAL AND PISTON IN CALIPER
4. INSTALL CYLINDER BOOT AND CYLINDER BOOT SETRING
CALIPER INSTALLATION
BR0ER±04
1. INSTALL FOLLOWING PARTS:
(a) 2 brake pads
(b) 2 anti±squeal springs
2. INSTALL CALIPER
(a) Temporarily install the caliper on the torque plate with 2installation bolts.
(b) Hold the sliding pin and torque the installation bolts.
Torque: 34 N Vm (350 kgf Vcm, 25 ft Vlbf)
3. CONNECT FLEXIBLE HOSE
Install the flexible hose on the caliper with 2 new gaskets.
Torque: 30 N Vm (310 kgf Vcm, 22 ft Vlbf)
HINT: Install the flexible hose lock securely in the lock hole
in the caliper.
4. FILL BRAKE R ESERVOIR WITH BRAKE FLUID AND
BLEED BRAKE SYSTEM
(See page BR±8)
5. CHECK FOR LEAKS
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BRAKE SYSTEM REAR BRAKE (Disc Brake)BR±43
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Page 1013 of 4087
REAR BRAKE
(Parking Brake)
COMPONENTS
BR04E±06
PARKING BRAKE DISASSEMBLY
BR04F±09
1. REMOVE REAR WHEEL
2. REMOVE REAR DISC BRAKE ASSEMBLY
(a) Remove the 2 mounting bolts and remove the disc brakeassembly.
(b) Suspend the disc brake so the hose is not stretched.
3. REMOVE DISC
(a) Place matchmarks on the disc and rear axle hub.
(b) Remove the disc. HINT: If the disc can not be removed easily, return the shoe
adjuster until the wheel turns freely.
BR±44
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BRAKE SYSTEM REAR BRAKE (Parking Brake)
WhereEverybodyKnowsYourName
Page 1014 of 4087
4. REMOVE SHOE RETURN SPRINGSUsing needle±nose pliers, remove the 2 shoe return springs.
5. REMOVE SHOE STRUT WITH SPRING
6. REMOVE FRONT SHOE ADJUSTER AND TENSION SPRING
(a) Slide out the front shoe and remove the shoe adjuster.
(b) Disconnect the tension spring and remove the front shoe.
7. 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.
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BRAKE SYSTEM REAR BRAKE (Parking Brake)BR±45
WhereEverybodyKnowsYourName
Page 1015 of 4087

PARKING BRAKE COMPONENTS
INSPECTION AND REPAIR
BR04G±0B
1. INSPECT DISASSEMBLED PARTSInspect the disassembled parts for wear, rust or damage.
2. MEASURE BRAKE SHOE LINING THICKNESS Using a scale, measure the thickness of the shoe lining.
Standard thickness:
2.5 mm (0.098 in.)
Minimum thickness: 1.0 mm (0.039 in.)
If the lining thickness is at the minimum thickness or less, or
if there is extremely uneven wear, replace the brake shoe.
3. MEASURE BRAKE DISC INSIDE DIAMETER Using a vernier caliper, measure the inside diameter of the
disc.
Standard inside diameter:
190 mm (7.48 in.)
Maximum inside diameter: 191 mm (7.52 in.)
Replace the disc if the inside di ameter is at the maximum val-
ue or more. Replace the disc or grind it with a lathe if the disc
is scored or is worn unevenly.
4. INSPECT P ARKING BRAKE LINING AND DISC FOR
PROPER CONTACT
Apply chalk to the inside surface of the disc, then grind down
the brake shoe lining to fit. If the contact between the disc and
the brake shoe lining is improper, repair it using a brake shoe
grinder or replace the brake shoe assembly.
5. MEASURE CLEARANCE BETWEEN PARKING BRAKE SHOE AND LEVER
Using a feeler gauge, measure the clearance.
Standard clearance:
Less than 0.35 mm (0.0138 in.)
If the clearance is not within the specification, replace the
shim with one of the correct size.
BR±46
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BRAKE SYSTEM REAR BRAKE (Parking Brake)
WhereEverybodyKnowsYourName
Page 1016 of 4087
Thickness mm(in.) Thickness mm(in.)
0.3 (0.012) 0.9 (0.035)
0.6
(0.024)
6. IF NECESSARY, REPLACE SHIM
(a) Remove the parking brake shoe lever, and install the correct
size shim.
(b) Install the parking brake shoe lever with a new Cwasher.
(c) Remeasure the clearance.
PARKING BRAKE ASSEMBLY
BR0ES±04
HINT: Assemble the parts in the correct direction, as shown.
1. APPLY HIGH TEMPERATURE GREASE ON BACK± ING PLATE
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BRAKE SYSTEM REAR BRAKE (Parking Brake)BR±47
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