Page 745 of 6020
5C-46 BRAKES
RUW 55CSH000401
Important Operations
4. Spring; shoe hold
Push the shoe hold spring toward the brake shoe and hold it
(1). Rotate the spring to remove it from the shoe hold pin (2).
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
• W heel 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, 4 ×4 5.0 (0.197) 1.0 (0.039)
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Page 746 of 6020
BRAKES 5C-47
Clean wheel Cylinder Parts
Always use clean brake fluid to clean wheel cylinder parts.
Note:
Do not use mineral based cleaning solvents such as
gasoline, kerosene, acetone, paint thinner, or carbon
tetrachloride.
Piston Cups
Inspect the piston cups for wear, distortion, fatigue or other
abnormal conditions.
Measuring the Brake Drum
mm (in)
Standard Limit
Inside diameter 254 (10.000) 255.5 (10.059)4×2
(Except HIGH
RIDE) Run out 0.08 (0.003) 0.15 (0.006)
Inside diameter 295 (11.614) 296.5 (11.673)4×2
(HIGH RIDE)4 ×4 Run out 0.08 (0.003) 0.15 (0.006)
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Page 747 of 6020
5C-48 BRAKES
REASSEMBLY
RTW 75CMF000601
MINOR COMPONENTS
Reassembly Steps
Wheel cylinder Assembly
▲ 1. Piston assembly
2. Cup; piston
3. Return spring
4. Boot; piston
▲ 5. Bleeder
6. Cap; bleeder
MAJOR COMPONENTS
Reassembly Steps
7. Back plate
8. Cover
▲ 9. W heel cylinder assembly
▲ 10. Bolt; wheel cylinder
▲ 11. Shoe; leading
▲ 12. Lever; parking
▲ 13. W asher; lever
▲ 14. Retainer
15. Spring; lever return
▲
16. Shoe; trailing
▲ 17. Spring; shoe to shoe, upper
▲ 18. Adjuster assembly
19. Spring; shoe to shoe; lower
▲ 20. Lever; adjuster
▲ 21. Ring; Adjuster lever
▲ 22. Spring; shoe hold
▲ 23. Pin; shoe hold
24. Spring; adjuster
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Page 748 of 6020

BRAKES 5C-49
Important Operations
Note:
• W ash the disassembled parts in clean brake fluid.
• Use compressed air to clean the ports.
• Protect the disassembled part surfaces from contamination
by dust and other foreign material.
• Before reassembly, check the part surfaces fo
r
contamination with dust or other foreign material.
• Be sure to replace the designated parts with new ones.
1. Piston Assembly
Install new piston cups on each piston so that the flared end of
the cups are turned to the inboard side of the pistons.
Attach the return spring and the boot to the piston.
Be sure to use new piston cup and boot.
RTW 55CSH000201
•
Apply brake fluid to the pistons and the inner face of the
boots.
• Note the direction of piston cup (1).
• Apply rubber grease to the boots (2) as shown in the
illustration.
5. Bleeder
Torque N ⋅m (kgf ⋅m/Ib ⋅in)
6 - 8 (0.6 – 0.8 / 52 - 69)
9. Wheel Cylinder Assembly
10. Bolt; Wheel cylinder
Torque N ⋅m (kgf ⋅m/Ib ⋅in)
14 - 18 (1.4 – 1.8 / 122 - 156)
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Page 749 of 6020

5C-50 BRAKES
308R300008
11. Shoe; leading
• Be sure to use new spring; shoe hold.
12. Lever; parking
13. Washer; lever
14. Retainer
Install the lever, the washer and the retainer to the leading
brake shoe.
•
Apply grease to the sliding surfaces of the lever and
brake shoe.
• Be sure to use new retainer and washer.
305R300009
16. Shoe; trailing
• Be sure to use new spring; shoe hold.
17. Spring; shoe to shoe, upper
18. Adjuster assembly 1. Apply grease to each of the parts shown in the illustration before installing the brake shoe.
• Lever; adjuster-shoe
• Adjuster-shoe
2. Clean the adjuster bolt (5) and the adjuster rods (1) (4).
Apply grease to the threaded portion of the adjuster bolt.
3. Install the adjuster rod to the adjuster bolt.
4.
Apply grease to the adjuster arm ends (2) (3). Set the
spring upper to the adjuster arm, then install them to the
brake shoe.
305R300010
5. Before setting the brake shoes, apply grease to the back
plate portions (1) contacting the brake shoe edge as
shown in the illustration.
6.
Apply grease to the wheel cylinder parts contacting the
brake shoe (2).
7. Install the brake shoe.
Note:
• Be careful not to damage the wheel cylinder dust cover.
• Do not allow the wheel cylinder piston to fly free.
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BRAKES 5C-51
20. Lever; adjuster
21. Ring; Adjuster lever • Apply grease to the lever adjuster sliding surface. Install
the lever adjuster and the ring to the shoe; trailing.
• Be sure to use a new ring.
RUW 55CSH000501
22. Spring; shoe hold
23. Pin; shoe hold • Install the brake drum.
• Install the rear wheel.
• If the wheel cylinder has been removed, the brake
system must be bled.
• Pump the brake pedal 10 times. Check that there is little
or no stroke length variation as the pedal is pumped.
• Adjust the lining clearance.
•
Brake Line
Torque N ⋅m (kgf ⋅m/Ib ⋅ft)
13 - 19 (1.3 - 1.9 / 9 - 14)
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Page 751 of 6020
5C-52 BRAKES
BRAKE CONTROL
REMOVAL AND INSTALLATION
BRAKE PEDAL ASSEMBLY
This illustration is based on the RHD model
310R300001
Removal Steps
1. Nut; Fulcrum pin
2. Pin; Fulcrum, pedal to bracket
3. Pedal arm
4. Return spring
5. Pedal pad
Installation steps
To install, follow the removal procedure in
reverse order.
Before installation, apply grease to the entire
circumference of the fulcrum pin (2).
Refer to “SERVICING” in this section for
adjustment procedure of brake pedal.
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Page 752 of 6020
BRAKES 5C-53
MASTER CYLINDER
REMOVAL AND INSTALLATION
MASTER CYLINDER ASSEMBLY
This illustration is based on the RHD model
RTW 75CMF000901
Removal Steps
▲ 1. Brake line
2. Nut; Master cylinder to vacuum booster
3. Master cylinder assembly
Installation Steps
3. Master cylinder assembly
▲ 2. Nut; Master cylinder to vacuum booster
▲ 1. Brake line
RTW 75CSH002701
Important Operation - Removal
1. Brake Line
Be very careful not to spill brake fluid on the painted surface.
Damage to the painted surface will result.
Important Operation - Installation
2. Nut; Master Cylinder to Vacuum Booster
Torque N ⋅m (kgf ⋅m/lb ⋅ft)
10 – 16 (1.0 – 1.6 / 7 – 12)
1. Brake Line
Torque N ⋅m (kgf ⋅m/lb ⋅ft)
13 – 19 (1.3 – 1.9 / 9 – 14)
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