Page 465 of 4264
BRAKES 5C-39
DISASSEMBLY
CALIPER ASSEMBLY
Disassembly Steps
1. Bleeder with cap
2. Piston
3. Dust seal; piston
4. Ring seal
5. Body; caliper
Important Operations
2. Piston (with Ring Seal)
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 dust seal.
CAUTION:
Do not place your fingers in front of the piston in an
attempt to catch or protect it when applying compressed
air.
Page 466 of 4264
5C-40 BRAKES
INSPECTION AND REPAIR
Make necessary correction or parts replacement if wear damage or any other abnormal conditions are found
through inspection.
Rotor
Caliper body
Cylinder bore
Piston
Support bracket
Lock bolt
Guide pin
Visual Check
Inspect the following parts for wear, bending, distortion,
cracking, corrosion, or other abnormal conditions.
Rotor
Thickness (t) mm(in)
Standard Replacement
thickness (Discard)
4
2 26.0 (1.024) 24.6 (0.969)
4
2 HIGH RIDE
44 27.0 (1.063) 25.6 (1.008)
Run out
Limit mm(in)
0.075 (0.0029)
Before inspection, adjust the wheel bearing correctly.
Using a dial gauge, measure the run out at the 10mm inside
position from rotor out side edge of disc pad contact surface.
Parallelism (Total circumferential thickness variation)
Limit mm(in)
0.023 (0.0009)
Contact surface must be within 0.023mm at the 10mm inside
position from rotor out side edge.
(Measurement; shall be measure more than 8 position at
circumferential direction.)
Page 467 of 4264
BRAKES 5C-41
Thickness of Disc Pad
Thickness (t) mm(in)
Standard Limit
10.0 (0.394) 1.8 (0.071)
Replace the front disc pad whenever the pad wear indicator
makes a squeaking noise or when the pad is worn to within 1.8
mm of the shoe table.
All four brake pads should be replaced together.
302R300019
Seal and Boot
The dust seal, dust boot and ring seal are to be replaced each
time the caliper is overhauled.
Discard thee used rubber parts.
Page 468 of 4264
5C-42 BRAKES
REASSEMBLY
CALIPER ASSEMBLY
Disassembly Steps
1. Body ; caliper
2. Ring seal
3. Dust seal ; piston
4. Piston
5. Bleeder
6. Cap
Important Operations
1. Body ; Caliper
2. Ring Seal
Apply clean brake fluid to the ring seal and cylinder wall, then
insert the ring seal into the cylinder.
Ensure that the piston ring seal are not twisted in the caliper
bore grooves.
Page 469 of 4264

BRAKES 5C-43
3. Dust seal ; Piston
Install the dust seal on the pistons.
4. Piston
Apply clean brake fluid to the piston, the dust seal is certainly
put into the slot on the piston and attach the caliper.
When inserting the piston into the cylinder, use finger pressure
only. Do not use a mallet or other impact tools, since damage
to the cylinder wall or ring seal can result.
The movement of a caliper piston into a caliper bore should be
smooth and even. If a caliper piston is frozen or difficult to
bottom, the caliper requires overhaul or replacement.
RTW35CSH000701
When not entering with a finger, insert a discarded inner brake
pad (2) or block of wood in front of the pistons. Using 2 large
C-clamps (1) installed over the body of the caliper (3) and
against the brake pad or block of wood, slowly bottom the
pistons evenly into the bores.
Insert the dust seal ring into the dust seal.
CAUTION:
Piston made by plastic material.
Don’t must be hit on the piston by hammer etc. and don’t
grasp to face of piston by pliers.
5. Bleeder
Torque Nm(kgfm/Ibin)
9 – 16 (0.9 – 1.6 / 78 - 139)
6. Cap
Page 470 of 4264
5C-44 BRAKES
REAR DRUM BRAKE ASSEMBLY
DISASSEMBLY
First, disassemble the brake drum. Then disassemble the rear brake assembly.
Refer to the “REAR AXLE ” section for the brake drum disassembly procedure.
RTW35CMF000201
MAJOR COMPONENTS
Disassembly Steps
1. Spring ; adjuster
2. Ring ; Adjuster lever
3. Lever ; adjuster
4. Spring ; Shoe hold
5. Pin ; Shoe hold
6. Spring ; Shoe to shoe, lower
7. Adjuster assembly
8. Spring ; shoe to shoe, upper
9. Shoe ; leading
10. Shoe ; trailing
11. Spring ; lever return
12. Retainer
13. Washer ; lever
14. Lever ; parking
15. Bolt ; wheel cylinder
16. Wheel cylinder assembly
17. Cover
18. Back plate
MINOR COMPONENTS
Disassembly Steps
Wheel Cylinder Assembly (14)
19. Piston
20. Cup
21. Boot ; piston
22. Return spring
23. Bleeder
24. Cap ; bleeder
Page 471 of 4264
BRAKES 5C-45
P1010008
Important Operations
4. Spring ; shoe hold
Push the shoe hold spring toward the brake shoe and hold it.
Rotate the spring to remove it from the shoe hold pin.
6. Spring ; shoe to shoe, lower
Slide the brake shoes and lower spring toward the ground.
Remove the lower spring.
INSPECTION AND REPAIR
Make necessary correction or parts replacement if wear damage or any other abnormal conditions are found
through inspection.
Brake drum
Back plate
Brake lining
Wheel cylinder body
Piston
Piston cup
Return spring
Visual check
Inspect the following parts for wear scuffs, scratches,
corrosion, stains, deterioration, or other abnormal conditions.
Thickness of the Brake Lining
Thickness mm(in)
standard (T) Limit (t)
4
2 5.0 (0.197) 1.0 (0.039)
4
2 HIGH RIDE
4
4 5.0 (0.197) 1.0 (0.039)
Page 472 of 4264
5C-46 BRAKES
Clean wheel Cylinder Parts
Always use clean brake fluid to clean wheel cylinder parts.
Note:
Do not use mineral-vase cleaning solvents such as
gasoline, kerosene, acetone, paint thinner, or carbon
tetrachloride.
Piston Cups
Inspect the piston cups for wear, distortion, fatigue, fatigue or
other abnormal conditions.
Measuring the Brake Drum
mm(in)
Standard Limit
Inside diameter 254 (10.000) 255.5 (10.059)
Run out 0.08 (0.003) 0.15 (0.006)
Inside diameter 295 (11.614) 296.5 (11.673)TFR (HIGH RIDE)
TFS Run out 0.08 (0.003) 0.15(0.006)
TFR