Page 785 of 2100
5C±105 POWER±ASSISTED BRAKE SYSTEM
Minimum wear dimension: 16.6 mm (0.654 in)
Refinish dimension: 16.97 mm (0.668 in)
420RW002
Rear Drum (In Disc) Inside Diameter
Check
Check the rear drum inside diameter by measuring at
more than two portions as shown in the illustration.
If the inside diameter is greater than the limit, replace the
rear rotor.
Standard: 210.0 mm (8.27 in)
Limit: 211.4 mm (8.32 in)
420RS035
Page 786 of 2100

5C±106
POWER±ASSISTED BRAKE SYSTEM
Rear Disc Brake Caliper Assembly (4y4 Model)
Rear Disc Brake Caliper Assembly and Associated Parts
306RW007
Legend
(1) Brake Flexible Hose
(2) Clip
(3) Lock Bolt(4) Support Bracket
(5) Guide Bolt
(6) Pad Assembly with Shim
(7) Caliper Assembly
Removal
1. Raise the vehicle and support with suitable safety
stands.
2. Remove wheel and tire assembly, referring to
Wheels
and Tires System
in Section 3E.
3. Remove the bolt and gaskets, then disconnect the
flexible hose from the caliper and after disconnecting
the flexible hose (1), cap or tape the openings to
prevent entry of foreign material.
306RW008
4. Since the brake fluid flows out from the connecting
coupler, place a drain pan under the vehicle.
5. Remove lock bolt (3).
6. Remove guide bolt (2).
306RW009
7. Remove caliper assembly.
8. Remove support bracket with pad assembly and take
care not to damage the flexible brake hose when
removing the support bracket.
9. Remove pad assembly with shim and mark the lining
locations if they are to be reinstalled.
Page 787 of 2100
5C±107 POWER±ASSISTED BRAKE SYSTEM
10. Remove clip.
Installation
1. Install clip (4).
306RW010
2. Apply special grease (approximately 0.2 g) to both
contacting surfaces of the inner shims (5). Wipe off
extruded grease after installing. Install pad assembly
with shim.
306RW011
Legend
(5) Inner Shim
(6) Wear indicator
3. Install support bracket and tighten the bolt (7) to the
specified torque.
Torque: 103 N´m (76 lb ft)
306RW012
4. Install caliper assembly.
5. Install lock bolt and guide bolt (8) and tighten the bolt
to the specified torque.
Torque: 44 N´m (32 lb ft)
306R200004
6. Install brake flexible hose, always use new gaskets
and be sure to put the hooked edge of the flexible
hose end into the anti±rotation cavity then tighten the
eye±bolt (9) to the specified torque.
Torque: 35 N´m (26 lb ft)
Page 788 of 2100
5C±108
POWER±ASSISTED BRAKE SYSTEM
302RW017
7. Install the wheel and tire assembly, referring to
Wheels and Tires System in Section 3E.
8. Bleed brakes. Refer to
Hydraulic Brakes in this
section.
Rear Disc Brake Caliper (4y4 Model)
Rear Disc Brake Caliper Disassembled View
306RW014
Legend
(1) Guide Bolt
(2) Lock Bolt
(3) Bleeder with Cap
(4) Caliper Body(5) Piston Seal
(6) Piston
(7) Dust Boot: Piston
(8) Dust Boot Ring
(9) Dust Boot: Guide Bolt and Lock Bolt
Page 789 of 2100

5C±109 POWER±ASSISTED BRAKE SYSTEM
Disassembly
1. Remove guide bolt.
2. Remove lock bolt.
3. Remove dust boot; guide bolt and lock bolt.
4. Remove dust boot ring, using a small screwdriver.
302RS016
5. Insert a block of wood into the caliper and force out
the piston by blowing compressed air into the caliper
at the flexible hose attachment. This procedure must
be done prior to removal of the dust boot.
Remove piston.
WARNING: D O N O T P L A C E Y O U R F I N G E R S I N
FRONT OF THE PISTON IN AN ATTEMPT TO CATCH
OR PROTECT IT WHEN APPLYING COMPRESSED
AIR. THIS COULD RESULT IN PERSONAL INJURY.
CAUTION: Use just enough air to ease the piston
out of the bore. If the piston is blown out, it may be
damaged.
302RS017
6. Remove dust boot: piston.
7. Remove piston seal.
8. Remove bleeder with cap.
9. Remove caliper body.
Inspection and Repair
Make necessary parts replacement, if wear, damage,
corrosion or any other abnormal conditions are found
through inspection.
Check the following parts:
Rotor
Cylinder body
Cylinder bore
Piston
Guide bolt, lock bolt
Support bracket
NOTE: The piston dust seal and dust boot are to be
replaced each time the caliper is overhauled. Discard
these used rubber parts and replace with new ones.
Reassembly
1. Install caliper body.
2. Install bleeder with cap and tighten the cap to the
specified torque.
Torque: 8 N´m (69 lb ft)
3. Install piston seal and apply special rubber grease to
the piston seal and cylinder wall, then insert the piston
seal into the cylinder. The special rubber grease is
included in the repair kit.
302RS018
4. When inserting the piston into the cylinder, use finger
pressure only and do not use a mallet or other impact
tool, since damage to the cylinder wall or piston seal
can result.
Install piston.
Page 790 of 2100
5C±110
POWER±ASSISTED BRAKE SYSTEM
302RS019
5. Apply special grease (approximately 1g) to the piston
and attach the dust boot to the piston and caliper.
Insert the dust boot ring into the dust boot.
302RS020
6. Install guide bolt and lock bolt dust boot.
7. Install the dust boot on the support bracket after
applying special grease (Approx. 1g) onto the dust
boot inner surface. Also apply special grease onto the
lock bolt and guide bolt setting hole of the support
bracket.
302RS021
8. Install lock bolt and guide bolt and tighten the bolt to
the specified torque.
Torque: 44 N´m (32 lb ft)
Page 791 of 2100
5C±111 POWER±ASSISTED BRAKE SYSTEM
Main Data and Specifications (4y4 Model)
General Specifications
TypeFloating, pin slide
Pad dimension33 cm (5.11 in)
Adjusting methodSelf±adjusting
Piston diameter41.3 mm (1.63 in)
Disc typeVentilated
Disc thickness18 mm (0.71 in)
Disc effective diameter269.2 mm (10.60 in)
Torque Specifications
E05RW005
Page 792 of 2100

5C±112
POWER±ASSISTED BRAKE SYSTEM
Brake Lining
Brake Lining and Associated Parts
305RW001
Legend
(1) Wheel and Tire Assembly
(2) Drum
(3) Hold-down Spring and Cup
(4) Hold-down Spring and Cups
(5) Lower Return Spring
(6) Upper (other) Return Spring
(7) Trailing Shoe Assembly with Parking Brake
Lever
(8) Leading Shoe Assembly with Upper (inner)
Return Spring(9) Upper (inner) Return Spring
(10) Auto Adjuster Lever
(11) Parking Brake Lever
(12) Adjuster Assembly
(13) Wave Washer
(14) Retainer
(15) Hold-down Pin
(16) Hold-down Pin
Removal
1. Raise the vehicle and support with suitable safety
stands.
2. Remove wheel and tire assembly (1).
Refer to
Wheel and Tires in Wheel and Tire System
section.
3. Remove Drum (2).
If difficulty is encountered in removing the drum:
± Mark the position of the drum to the axle.
± Make sure the parking brake is released.± Use a rubber mallet to tap gently on the outer rim of
the drum and/or around the inner drum. Be careful
to avoid damaging the drum.
4. Remove upper (other) return spring (6) and auto
adjuster lever.
5. Remove lower return spring (5).
6. Remove hold-down spring and cups (4) and
hold-down pin (15).
7. Remove adjuster assembly (12)
8. Remove leading shoe assembly (8) with upper (inner)
return spring (9).