Diesel Data: Automotive Repair
Home >> Toyota >> 2004 >> Solara L4-2.4L (2AZ-FE) >> Repair and Diagnosis >> Brakes and Traction Control >> Disc Brake System >> Service and Repair >> Rear

Rear






REAR DISC BRAKE
OVERHAUL

HINT: Use the same procedures for the RH side and LH side. The procedures listed below are for the LH side.

1. REMOVE REAR WHEEL
2. DRAIN BRAKE FLUID

NOTICE: Wash brake fluid off immediately if it adheres to any painted surface.

3. DISCONNECT FLEXIBLE HOSE
a. Remove the union bolt and gasket from the disc brake cylinder, then disconnect the flexible hose from the disc brake cylinder.
4. REMOVE REAR DISC BRAKE CYLINDER SLIDE PIN
a. Remove the cylinder slide pin and cylinder slide bush.
5. REMOVE REAR DISC BRAKE CYLINDER ASSY LH
a. Remove the cylinder slide pin and disc brake cylinder.
6. REMOVE DISC BRAKE PAD KIT REAR (PAD ONLY)
a. Remove the 2 brake pads with the anti squeal shims.
7. REMOVE REAR DISC BRAKE ANTI SQUEAL SHIM KIT
a. Remove the 2 anti squeal shims from each of 2 brake pads.
b. Remove the pad wear indicator plate from inner pad.
8. REMOVE REAR DISC BRAKE PAD SUPPORT PLATE
a. Remove the rear disc brake pad support plate No. 1.
b. Remove the rear disc brake pad support plate No.2.
9. REMOVE REAR DISC BRAKE BUSH DUST BOOT
a. Remove the 2 rear disc brake bush dust boots.
10. REMOVE REAR DISC BRAKE CYLINDER MOUNTING LH
a. Remove the 2 bolts and cylinder mounting LH.
11. REMOVE CYLINDER BOOT
a. Using a screwdriver, remove the set ring and disc cylinder boot.

NOTICE: Be careful not to damage the piston groove and cylinder groove.





12. REMOVE REAR DISC BRAKE PISTON
a. Place a shop rag, between the piston and the disc brake cylinder.
b. Use compressed air to remove the piston from the disc brake cylinder.

CAUTION: Do not place your fingers in front of the piston when using compressed air.

NOTICE: Do not spatter the brake fluid.





13. REMOVE PISTON SEAL
a. Using a screwdriver, remove the piston seal from the brake cylinder.

NOTICE: Do not damage the inner cylinder and the cylinder groove.

14. REMOVE REAR DISC BRAKE BLEEDER PLUG CAP
15. REMOVE REAR DISC BRAKE BLEEDER PLUG
16. INSPECT BRAKE CYLINDER AND PISTON
a. Check the cylinder bore and piston for rust or scoring. If necessary, replace the brake cylinder and piston.





17. INSPECT PAD LINING THICKNESS
a. Using a ruler, measure the pad lining thickness.
Standard thickness: 10.0 mm (0.394 inch)
Minimum thickness: 1.0 mm (0.039 inch)
If the pad lining thickness is equal to the minimum thickness or less, replace the brake pad.
18. INSPECT REAR DISC BRAKE PAD SUPPORT PLATE
a. Inspect the front disc brake pad support plate No.1 and front disc brake pad support plate No.2.

HINT: Make sure that both have sufficient rebound, have no deformation, cracks or wear, and that all rust and dirt is cleaned off. If necessary, replace the brake pad support plate.





19. INSPECT DISC THICKNESS
a. Using a micrometer, measure the disc thickness.
Standard thickness: 12.0 mm (0.472 inch)
Minimum thickness: 10.5 mm (0.413 inch)
If the disc thickness is less than the minimum, replace the disc.
20. REMOVE PARKING BRAKE SHOE ADJUSTING HOLE PLUG





21. REMOVE REAR DISC
a. Put matchmarks on the rear disc and the axle hub.





b. Release the parking brake, and remove the rear disc.

HINT: If the disc cannot be removed easily, turn the shoe adjuster until the wheel turns freely.

22. INSTALL REAR DISC
a. Aligning the matchmarks, install the rear disc.

HINT: When replacing the disc with a new one, select the installation position where the disc has the minimum runout.

23. INSTALL PARKING BRAKE SHOE ADJUSTING HOLE PLUG





24. INSPECT DISC RUNOUT
a. Check the bearing play in the axial direction and check for the axle hub runout.
b. Temporarily fasten the rear disc with hub nuts.
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
c. Using a dial indicator, measure the disc runout 10 mm (0.39 inch) away from the outer edge of the rear disc.
Maximum disc runout: 0.15 mm (0.0059 inch)
If the runout exceeds the maximum value, change the installation positions of the disc and axle so that the runout will become minimal. If the runout exceeds the maximum even when the installation positions are changed, grind the disc. If the disc thickness is less than the minimum, replace the rear disc.
25. ADJUST PARKING BRAKE SHOE CLEARANCE
26. TEMPORARILY TIGHTEN REAR DISC BRAKE BLEEDER PLUG
a. Temporarily tighten the bleeder plug to the disc brake cylinder.
27. INSTALL REAR DISC BRAKE BLEEDER PLUG CAP
28. INSTALL PISTON SEAL
a. Apply lithium soap base glycol grease to a new piston seal.
b. Install the piston seal to the disc brake cylinder.
29. INSTALL REAR DISC BRAKE PISTON
a. Apply lithium soap base glycol grease to the piston.
b. Install the piston to the disc brake cylinder.

NOTICE: Do not install the piston forcibly in the rear disc brake cylinder sub-assy.

30. INSTALL CYLINDER BOOT
a. Apply lithium soap base glycol grease to a new cylinder boot.
b. Install the cylinder boot to the disc brake cylinder.

NOTICE: Install the boot securely to the grooves of the cylinder and piston. Do not damage the cylinder boot.

c. Using a screwdriver, install a new set ring.

NOTICE: Do not damage the cylinder boot.

31. INSTALL REAR DISC BRAKE CYLINDER MOUNTING LH
a. Install the cylinder mounting LH with the 2 bolts.
Torque: 62 Nm (630 kgf-cm, 46 ft. lbs.)
32. INSTALL REAR DISC BRAKE CYLINDER SLIDE PIN
a. Install the cylinder slide pin (lower) with the cylinder slide bush.
Torque: 43 Nm (440 kgf-cm, 32 ft. lbs.)
33. INSTALL REAR DISC BRAKE BUSH DUST BOOT
a. Install the rear disc brake bush dust boot.
1. Apply lithium soap base glycol grease to seal surface of 2 new bush dust boots.
2. Install the 2 bush dust boots to each cylinder slide pin.
34. INSTALL REAR DISC BRAKE PAD SUPPORT PLATE
a. Install the rear disc brake pad support plate No.1.
b. Install the rear disc brake pad support plate No.2.
35. INSTALL REAR DISC BRAKE ANTI SQUEAL SHIM KIT
a. Coat both sides of No.1 anti squeal shim with disc brake grease, and install the shim together with No.2 anti squeal shim to the outer pad.

NOTICE: When replacing worn pads, the anti squeal shims must be replaced together with the pads.

b. Coat both sides of No.4 anti squeal shim with disc brake grease, and install the shim together with No.3 anti squeal shim to the inner pad.

NOTICE: When replacing worn pads, the anti squeal shims must be replaced together with the pads.

c. Install the pad wear indicator plate to the inner pad.
36. INSTALL DISC BRAKE PAD KIT REAR (PAD ONLY)
a. Install the 2 brake pads with the anti squeal shims.

NOTICE: There should be no oil or grease on the friction surface of the pads and the disc. Inner pad is installed with indicator plate facing downward.

37. INSTALL REAR DISC BRAKE CYLINDER SLIDE PIN
a. Apply lithium soap base glycol grease to the cylinder slide pin.
b. Install and torque the cylinder slide pin (upper) to the disc brake cylinder assembly.
Torque: 43 Nm (440 kgf-cm, 32 ft. lbs.)
38. CONNECT FLEXIBLE HOSE
a. Connect a new gasket and flexible hose with the union bolt.
Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)
39. FILL RESERVOIR WITH BRAKE FLUID
40. BLEED MASTER CYLINDER
SST 09023-00100
41. BLEED BRAKE LINE
42. CHECK FLUID LEVEL IN RESERVOIR
43. CHECK BRAKE FLUID LEAKAGE
44. INSTALL REAR WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)


Diesel-Data.com