Page 414 of 2395

SBR020B
ThicknessNBBR0035S0202Thickness variation (At least 8 positions):
Maximum 0.015 mm (0.0006 in)
If thickness variation exceeds the specification, turn rotor with on-
car brake lathe.
Rotor repair limit:
26.0 mm (1.024 in)
SBR574
AssemblyNBBR00361. Insert piston seal into groove on cylinder body.
2. With piston boot fitted to piston, insert piston boot into groove
on cylinder body and install piston.
3. Properly secure piston boot
SBR387D
InstallationNBBR0037CAUTION:
IRefill with new brake fluid ªDOT 3º.
INever reuse drained brake fluid.
1. Install caliper assembly.
2. Install brake hose to caliper securely.
3. Install all parts and secure all bolts.
4. Bleed air. Refer to ªBleeding Brake Systemº, BR-8.
Brake Burnishing ProcedureNBBR0086When experiencing soft brake pedal feel at very low mileage, or
after replacing the rotor, burnish the brake pad contact surfaces
according to the following procedures.
CAUTION:
Only perform this procedure under safe road and traffic con-
ditions. Use extreme caution.
1. Drive the vehicle on a straight smooth road at 50 km/h (31
MPH).
2. Use medium brake pedal/foot effort to bring the vehicle to a
complete stop from 50 km/h (31 MPH). Adjust brake pedal/foot
pressure such that vehicle stopping time equals 3 to 5 sec-
onds.
3. To cool the brake system, drive the vehicle at 50 km/h (31
MPH) for 1 minute without stopping.
4. Repeat steps 1 to 3 10 times or more to complete the burnish-
ing procedure.
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FRONT DISC BRAKE
Inspection (Cont'd)
BR-25
Page 415 of 2395
ComponentsNBBR0038
SBR757DA
1. Shoe hold pin
2. Plug
3. Back plate
4. Check plug
5. Spring
6. Shoe (leading side)
7. Air bleeder
8. Spring
9. Piston cup10. Piston
11. Boot
12. Retainer ring
13. Toggle lever
14. Wave washer
15. Shoe (trailing side)
16. Adjuster
17. Boot
18. Piston19. Piston cup
20. Wheel cylinder
21. Adjuster lever
22. Spring seat
23. Shoe hold spring
24. Retainer
25. Adjuster spring
26. Return spring (upper)
27. Return spring (lower)
RemovalNBBR0039WARNING:
Clean brake lining with a vacuum dust collector to minimize
the hazard of airborne asbestos or other materials.
CAUTION:
Make sure parking brake lever is released completely.
SBR264CA
1. Release parking brake lever fully, then remove drum.
If drum is hard to remove, the following procedures
should be carried out.
a. Remove plug. Then shorten adjuster to make clearance
between brake shoe and drum as shown.
REAR DRUM BRAKE
Components
BR-26
Page 416 of 2395
SBR093A
b. Tighten the two bolts gradually.
SBR266CA
2. After removing shoe hold pin by rotating push retainer, remove
leading shoe then remove trailing shoe. Remove spring by
rotating shoes in direction arrow.
Be careful not to damage wheel cylinder piston boots.
3. Remove adjuster.
SBR267CA
4. Disconnect parking brake cable from toggle lever.
Be careful not to damage parking brake cable when separat-
ing it.
SBR093B
5. Remove retainer ring with a suitable tool. Then separate toggle
lever and brake shoe.
SBR816B
InspectionNBBR0040WHEEL CYLINDERNBBR0040S01ICheck wheel cylinder for leakage.
ICheck for wear, damage and loose conditions.
Replace if any such condition exists.
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REAR DRUM BRAKE
Removal (Cont'd)
BR-27
Page 418 of 2395
SBR217B
3. Shorten adjuster by rotating it.
IPay attention to direction of adjuster.
Wheel Screw Depression
Left Left-hand thread Yes
Right Right-hand thread No
SBR279B
4. Connect parking brake cable to toggle lever.
5. Install all parts.
Be careful not to damage wheel cylinder piston boots.
6. Check all parts are installed properly.
Pay attention to direction of adjuster assembly.
7. Install brake drum.
8. When installing new wheel cylinder or overhauling wheel
cylinder, bleed air. Refer to ªBleeding Brake Systemº, BR-8.
9. Adjust parking brake. Refer to ªAdjustmentº, ªPARKING
BRAKE CONTROLº, BR-31.
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REAR DRUM BRAKE
Installation (Cont'd)
BR-29
Page 1325 of 2395
RemovalNBEL0060S02011. Remove 4 bolts that secure wiper motor.
2. Detach wiper motor from wiper linkage at ball joint.
3. Remove wiper linkage.
Be careful not to break ball joint rubber boot.
InstallationNBEL0060S0202IGrease ball joint portion before installation.
1. Installation is the reverse order of removal.
MEL137M
Washer Nozzle AdjustmentNBEL0061IAdjust washer nozzle with suitable tool as shown in the figure
at left.
Adjustable range:±10É
MEL417N
Unit: mm (in)
*1 315 (12.40) *7 443 (17.44)
*2 227 (8.94) *8 250 (9.84)
*3 122 (4.80) *9 80 (3.15)
*4 220 (8.66) *10 430 (16.93)
*5 315 (12.40) *11 250 (9.84)
*6 145 (5.71) *12 57 (2.24)
*A: The diameters of these circles are less than 80 mm (3.15 in).
*B: The diameter of this circle is less than 120´80 mm (4.72´3.15 in).
*C: The diameter of this circle is less than 100´80 mm (3.94´3.15 in).
MEL074H
Washer Tube LayoutNBEL0062
FRONT WIPER AND WASHER
Removal and Installation (Cont'd)
EL-140
Page 2003 of 2395

CHASSIS AND BODY MAINTENANCENBMA0004S0102
Abbreviations: R = Replace. I = Inspect. Correct or replace if necessary. L = Lubricate
MAINTENANCE OPERATIONMAINTENANCE INTERVAL
Reference
Section
- Page or
- Content Title Perform at number of miles, kilo-
meters or months, whichever
comes first.Miles x 1,000
(km x 1,000)
Months3.75
(6)
37.5
(12)
611.25
(18)
915
(24)
1218.75
(30)
1522.5
(36)
1826.25
(42)
2130
(48)
2433.75
(54)
2737.5
(60)
3041.25
(66)
3345
(72)
3648.75
(78)
3952.5
(84)
4256.25
(90)
4560
(96)
48
Brake lines & cables I I I I MA-25
Brake pads, rotors, drums & linings I IIIIIIIMA-25, 26
Automatic transmission & all-mode
4WD transfer fluid & differential
gear oil (exc. LSD)NOTE (1) I I I I MA-21, 22, 23
LSD gear oil NOTE (1) I R I R MA-24
Steering gear, linkage & transfer
gear, axle & suspension partsIIIIIIIIMA-26
NOTE (6)
Tire rotation NOTE (2)MA-4
Drive shaft boots (
) IIIIIIIIAX-10, ªDrive
Shaftº
Propeller shaft NOTE (3) L LLLLLLLMA-23
Front wheel bearing grease (4x2) I I
Front wheel bearing
grease (
)NOTE (4) I R I RAX-4, ªFront
Wheel Bearingº
Exhaust system I IIIIIIIMA-21
Supplemental air bag systems NOTE (5)RS-14, ªMainte-
nance Itemsº
Ventilation air filter I RIRIRIRHA-159, ªVentila-
tion Air Filterº
ASCD vacuum hoses I I I IEL-237, ªASCD
ACTUATOR/
PUMP CHECKº
NOTE:
(1) If towing a trailer, using a camper or a car-top carrier, or driving on rough or muddy roads, change (not just inspect) fluid (A/T, all mode 4WD transfer)/differential gear oil (exc.
LSD) at every 30,000 miles (48,000 km) or 24 months, and change LSD gear oil every 15,000 miles (24,000 km) or 12 months.
(2) Refer to ªTire rotationº under the ªGENERAL MAINTENANCEº heading earlier in this section.
(3) The propeller shaft should be re-greased after being immersed in water.
(4) If operating frequently in water, replace grease every 3,750 miles (6,000 km) or 3 months.
(5) Inspect the air bag system 10 years after the date of manufacture noted on the FMVSS certification label.
(6) Refer to SU-5, ªFront Suspension Partsº and SU-16, ªRear Suspension Partsº, AX-3, ªFront Axle Partsº and AX-18, ªRear Axle Partsº.
PERIODIC MAINTENANCE
Schedule 1 (Cont'd)
MA-8
Page 2005 of 2395

CHASSIS AND BODY MAINTENANCENBMA0004S0202
Abbreviations: R = Replace. I = Inspect. Correct or replace if necessary. L = Lubricate
MAINTENANCE OPERATIONMAINTENANCE INTERVAL
Reference Section
- Page
or
- Content Title Perform at number of miles, kilometers
or months, whichever comes first.Miles x 1,000
(km x 1,000)
Months7.5
(12)
615
(24)
1222.5
(36)
1830
(48)
2437.5
(60)
3045
(72)
3652.5
(84)
4260
(96)
48
Brake lines & cablesIIIIMA-25
Brake pads, rotors, drums & liningsIIIIMA-25, 26
Automatic transmission & all-mode 4WD
transfer fluid & differential gear oil (exc.
LSD)IIIIMA-21, 22, 23
LSD gear oilIRIRMA-24
Steering gear, linkage & transfer gear,
axle & suspension partsIIMA-26
NOTE (4)
Tire rotation NOTE (1)MA-4
Drive shaft boots (
) IIIIAX-10, ªDrive shaftº
Propeller shaft NOTE (2)LLLLMA-23
Front wheel bearing grease (4x2) I I
Front wheel bearing grease (
) IRIRAX-4, ªFront Wheel
Bearingº
Exhaust systemI I MA-21
Supplemental air bag systems NOTE (3)RS-14, ªMaintenance
Itemº
Ventilation air filterRRRRHA-159, ªVentilation Air
Filterº
ASCD vacuum hosesIIIIEL-237, ªASCD
ACTUATOR/PUMP
CHECKº
NOTE:
(1) Refer to ªTire rotationº under the ªGENERAL MAINTENANCEº heading earlier in this section.
(2) The propeller shaft should be re-greased after being immersed in water.
(3) Inspect the air bag system 10 years after the date of manufacture noted on the FMVSS certification label.
(4) Refer to SU-5, ªFront Suspension Partsº and SU-16, ªRear Suspension Partsº, AX-3, ªFront Axle Partsº and AX-18, ªRear Axle Partsº.
PERIODIC MAINTENANCE
Schedule 2 (Cont'd)
MA-10
Page 2021 of 2395
SMA848B
Checking Drum BrakeNBMA0033WHEEL CYLINDERNBMA0033S01Check for leakage.
DRUMNBMA0033S02Check condition and inner surface.
Standard inner diameter:
295 mm (11.61 in)
Drum repair limit (Inner diameter):
296.5 mm (11.67 in)
SMA849B
LININGNBMA0033S03Check wear or damage.
Standard thickness:
6.1 mm (0.24 in)
Lining wear limit (Minimum thickness):
1.5 mm (0.059 in)
SMA870C
TEMPORARY METHOD FOR CHECKING LINING WEARNBMA0033S04Remove inspection hole plug and check for lining wear.
SMA874C
Checking Steering Gear, Linkage and Transfer
Gear
NBMA0034STEERING GEARNBMA0034S01ICheck gear housing and boots for looseness, damage and
grease leakage.
ICheck connection with steering column for looseness.
STEERING LINKAGENBMA0034S02ICheck ball joint, dust cover and other component parts for
looseness, wear, damage and grease leakage.
STEERING TRANSFER GEARNBMA0034S03ICheck gear box for looseness, damage and grease leakage.
CHASSIS AND BODY MAINTENANCE
Checking Drum Brake
MA-26