Service Manual
Contents
1. until the drum rotates slightly c Install the hole plug TO NEXT SECTION2. BR 29 REAR DRUM BRAKE COMPONENTS BRAKE REAR DRUM BRAKE O WHEEL CYLINDER BOOT REAR WHEEL CYLINDER COMPRESSION SPRING WHEEL CYLINDER PISTON Vox gt WHEEL CC CYLINDER BOOT O WHEEL CYLINDER gt CUP 6 WHEEL CYLINDER PISTON REAR WHEEL BRAKE CYLINDER ASSEMBLY BLEEDER PLUG CAP BRAKE TUBE REAR BRAKE SHOE KIT BLEEDER PLUG PARKING BRAKE SHOE LEVER LH REAR BRAKE HOLE PLUG C WASHER REAR BRAKE STRUT KIT REAR BRAKE SHOE REAR BRAKE AUTOMATIC ADJUST LEVER LH REAR BRAKE SHOE KIT REAR BRAKE SHOE HOLD DOWN SPRING CUP REAR BRAKE AUTOMATIC ADJUST LEVER REAR BRAKE SHOE TORSION SPRING RETURN SPRING REAR BRAKE DRUM _ TIGHTENING TORQUE N m kgf cm lt APPLY BRAKE GREASE 0 NON REUSEABLE PART C140727J09 BR 30 BRAKE REAR DRUM BRAKE DISASSEMBLY REMOVE REAR TIRE C136078 C137755 Y C136074 1 2 3 DRAIN BRAKE FLUID REMOVE REAR BRAKE DRUM a Release the parking brake and remove the brake drum HINT If the brake drum can not be removed easily remove the hole plug push up the automatic adjust lever from the service hole of the backing plate using a screwdriver Then use another screwdriver to turn the adjuster and retract it REMOVE REAR BRAKE SHOE KIT SST a 09703 30011 Using the SST disconnect the tension spr
3. here the shoe contacts b Using needle nose pliers install the parking brake cable to the parking brake shoe lever c Install the brake shoe rear side with the rear brake shoe hold down spring cup the rear brake shoe hold down spring and the rear brake shoe hold down spring pin BR 34 BRAKE REAR DRUM BRAKE C137755 C136078 d Hook the tension spring to the brake shoe rear side and install the rear brake strut kit e Install the rear brake shoe return spring from the back side of the brake shoe f Install the brake shoe front side with the rear brake shoe hold down spring cup the rear brake shoe hold down spring and the rear brake shoe hold down spring pin g Using the SST install the tension spring to the brake shoe front NOTICE Do not damage the wheel cylinder boot INSPECT REAR DRUM BRAKE INSTALLATION a Check that each part is properly installed NOTICE e Check that the wheel cylinder boot is not damaged and that there is no oil or grease on the part e Check that there is no oil or water on the surface of the shoe lining INSTALL REAR BRAKE DRUM ADJUST CLEARANCE BETWEEN BRAKE DRUM AND LINING a Using a screwdriver through the service hole extend the adjuster by turning it Extend the adjuster until the brake shoe comes into contact with the drum b Using another screwdriver lift up the automatic adjust lever Then turn the adjuster
4. ing from the brake shoe strut front side NOTICE Do not damage the wheel cylinder boot Remove the rear brake shoe hold down spring cup the rear brake shoe hold down spring and the rear brake shoe hold down spring pin Then remove the brake shoe front side Remove the rear brake shoe return spring Remove the tension spring from the brake shoe rear Then remove the rear brake strut kit Remove the rear brake shoe hold down spring cup the rear brake shoe hold down spring and the rear brake shoe hold down spring pin Then remove the brake shoe rear side Using needle nose pliers disconnect the parking brake cable 5 6 7 C136885 C136883 C136884J05 8 y 9 05 C057785J01 BRAKE REAR DRUM BRAKE REMOVE REAR BRAKE AUTOMATIC ADJUST LEVER LH a Remove the automatic adjust lever torsion spring and the clip Then remove the rear brake automatic adjust lever REMOVE PARKING BRAKE SHOE LEVER LH a Using a screwdriver remove the C washer and the parking brake shoe lever REMOVE REAR WHEEL BRAKE CYLINDER ASSEMBLY SST 09023 00100 HINT Disassembly and inspection of the rear wheel cylinder can be performed with the parking plate still installed Therefore do not remove the parking plate except when replacing the rear wheel cylinder or similar a Using the SST disconnect the brake tube from the wheel cylinder b Remove the bleeder plug cap c Remove the rea
5. maged HINT If there is any damage on the inside surface of the wheel cylinder body replace it with a new front disk brake cylinder assembly LH REASSEMBLY 6 y DA y la APPLY BRAKE GREASE C057785J08 1 INSTALL REAR WHEEL CYLINDER CUP KIT a Apply brake grease to 2 new wheel cylinder cups and install the cup to each of the 2 wheel cylinder pistons b Apply brake grease to 2 new wheel cylinder pistons c Install the rear wheel cylinder compression spring and the 2 wheel cylinder pistons to the wheel cylinder body d Install 2 new wheel cylinder boots to the wheel cylinder body 2 INSTALL REAR WHEEL BRAKE CYLINDER ASSEMBLY SST 09023 00100 C136884J06 C136883 C062256J01 C136885 C136074 BRAKE REAR DRUM BRAKE a Install the rear wheel cylinder with the bolt Torque 9 5 N m 97 kgf cm b Temporarily install the rear drum brake bleeder plug c Install the bleeder plug cap d Using the SST connect the brake tubes to the wheel cylinder Torque 15 2 N m 155 kgf cm INSTALL PARKING BRAKE SHOE LEVER LH a Using new C washer install the parking brake shoe lever to the brake shoe rear side INSTALL REAR BRAKE AUTOMATIC ADJUST LEVER LH a Install the automatic adjust lever and torsion spring to the brake shoe front side INSTALL REAR BRAKE SHOE KIT SST 09703 30011 a Apply brake grease to a part of the packing plate w
6. r drum brake bleeder plug d Remove the 2 bolts then remove the rear wheel cylinder REMOVE REAR WHEEL BRAKE CYLINDER CUP KIT a Remove the 2 wheel cylinder boots from the wheel cylinder piston b Remove the 2 wheel cylinder pistons c Remove the wheel cylinder cups from each wheel cylinder piston d Remove the rear wheel cylinder compression spring BRAKE REAR DRUM BRAKE BR 32 INSPECTION C093250J01 1 INSPECT BRAKE DRUM INSIDE DIAMETER a Using a vernier caliper measure the inside diameter of the drum Maximum diameter 229 6 mm Reference value 228 6 mm when new 2 INSPECT REAR DRUM BRAKE SHOE LINING THICKNESS a Using vernier calipers measure the thickness of the shoe lining Maximum thickness 1 0 mm Reference value 5 0 mm when new NOTICE Replacement of the brake shoe lining should not be performed for only a single side of the vehicle To prevent the vehicle from pulling to one side 3 INSPECT BRAKE DRUM AND LINING CONTACT a Apply chalk to the inside of the brake drum and move the lining back and forth across the chalked surface inside the drum Standard No significant contact problems b If the contact is not good shape the brake shoe lining to improve fit NOTICE After completing the inspection wipe off the chalk R00156401 4 CHECK REAR WHEEL BRAKE CYLINDER ASSEMBLY a Check that the inside surface of the wheel cylinder body is not da
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