Rear
REAR DISC BRAKECOMPONENTS (Part 1):
COMPONENTS (Part 2):
DISASSEMBLY
HINT:
^ Use the same procedures for the RH side and LH side.
^ The procedures listed below are for the LH side.
1. REMOVE REAR BRAKE
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 the 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 bushing.
5. REMOVE REAR DISC BRAKE CYLINDER ASSEMBLY
(a) Remove the cylinder slide pin and disc brake cylinder.
6. REMOVE REAR DISC BRAKE PAD
(a) Remove the 2 brake pads with the anti squeal shims.
7. REMOVE REAR DISC BRAKE ANTI SQUEAL SHIM
(a) Remove the 2 rear 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 No. 1 rear disc brake pad support plate.
(b) Remove the No. 2 rear disc brake pad support plate.
9. REMOVE REAR DISC BRAKE BUSHING DUST BOOT
(a) Remove the 2 rear disc brake bushing dust boots.
10. REMOVE REAR DISC BRAKE CYLINDER MOUNTING
(a) Remove the 2 bolts and cylinder mounting.
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. REMOVE PARKING BRAKE SHOE ADJUSTING HOLE PLUG
17. 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.
REASSEMBLY
1. 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.
2. INSTALL PARKING BRAKE SHOE ADJUSTING HOLE PLUG
3. ADJUST PARKING BRAKE SHOE CLEARANCE
4. TEMPORARILY TIGHTEN REAR DISC BRAKE BLEEDER PLUG
(a) Temporarily tighten the bleeder plug to the disc brake cylinder.
5. INSTALL REAR DISC BRAKE BLEEDER PLUG CAP
6. 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.
7. 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-assembly.
8. 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.
9. INSTALL REAR DISC BRAKE CYLINDER MOUNTING
(a) Install the cylinder mounting with the 2 bolts.
Torque: 62 Nm (630 kgf-cm, 46 ft. lbs.)
10. INSTALL REAR DISC BRAKE BUSHING DUST BOOT
(a) Install the rear disc brake bushing dust boot.
(b) Apply lithium soap base glycol grease to seal surface of 2 new bushing dust boots.
(c) Install the 2 bushing dust boots to the rear disc brake cylinder mounting.
11. 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.
12. INSTALL REAR DISC BRAKE ANTI SQUEAL SHIM
(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.
13. INSTALL REAR DISC BRAKE PAD
(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.
14. INSTALL REAR DISC BRAKE CYLINDER ASSEMBLY
(a) Install the rear disc brake cylinder assembly to the rear disc brake cylinder mounting.
15. INSTALL REAR DISC BRAKE CYLINDER SLIDE PIN
(a) Install the cylinder slide bushing to the cylinder slide pin (lower).
(b) Apply lithium soap base glycol grease to the cylinder slide pin.
(c) Install the cylinder slide pin to the rear disc brake cylinder assembly.
Torque: 43 Nm (440 kgf-cm, 32 ft. lbs.)
16. CONNECT FLEXIBLE HOSE
(a) Install a new gasket and connect flexible hose with the union bolt.
Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)
17. FILL RESERVOIR WITH BRACKET FLUID
18. BLEED BRAKE MASTER CYLINDER
19. BLEED BRAKE LINE
20. BLEED BRAKE ACTUATOR (w/ VSC)
21. CHECK FLUID LEVEL IN RESERVOIR
22. CHECK FOR FLUID LEAK
23. INSTALL REAR WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)