Rear
REAR BRAKECOMPONENTS (Part 1):
COMPONENTS (Part 2):
DISASSEMBLY
1. REMOVE REAR BRAKE PAD
(a) Remove the 2 brake pads with the rear anti-squeal shim.
2. REMOVE REAR ANTI-SQUEAL SHIM
(a) Remove the 2 rear anti-squeal shims and the 2 pad wear indicator from each pad.
3. REMOVE NO. 1 REAR DISC BRAKE PAD SUPPORT PLATE
(a) Remove the No. 1 rear disc brake pad support plate from the rear disc brake cylinder mounting.
4. REMOVE NO. 2 REAR DISC BRAKE PAD SUPPORT PLATE
(a) Remove the No. 2 rear disc brake pad support plate from the rear disc brake cylinder mounting.
5. REMOVE REAR DISC BRAKE CYLINDER MOUNTING
(a) Remove the 2 bolts and the rear disc brake cylinder mounting.
6. REMOVE REAR DISC BRAKE CYLINDER SLIDE PIN
(a) Remove the 2 rear disc brake cylinder slide pins (upper and lower) from the rear disc brake cylinder mounting.
7. REMOVE REAR DISC BRAKE BUSHING DUST BOOT
(a) Remove the 2 rear disc brake bushing dust boots from the rear disc brake cylinder mounting.
8. REMOVE CYLINDER BOOT
(a) Using a screwdriver, pry out the brake cylinder boot set ring and cylinder boot.
NOTICE: Be careful not to damage the rear disc brake piston and the rear disc brake cylinder assembly.
HINT: Tape the screwdriver tip before use.
9. REMOVE REAR DISC BRAKE PISTON
(a) Prepare a wooden plate to hold the rear disc brake piston.
(b) Place the wooden plate between the rear disc brake piston and the rear disc brake cylinder assembly.
(c) Use compressed air to remove the rear disc brake piston from the rear disc brake cylinder assembly.
CAUTION: Do not place your fingers in front of the rear disc brake piston when using compressed air.
NOTICE: Be careful not to spatter the brake fluid.
10. REMOVE PISTON SEAL
(a) Using a screwdriver, remove the rear disc brake piston seal from the rear disc brake cylinder assembly.
NOTICE: Be careful not to damage the inner cylinder and cylinder groove.
HINT: Tape the screwdriver tip before use.
11. REMOVE REAR DISC BRAKE BLEEDER PLUG CAP
(a) Remove the bleeder plug cap from the rear disc brake bleeder plug.
12. REMOVE REAR DISC BRAKE BLEEDER PLUG
(a) Remove the rear disc brake bleeder plug from the rear disc brake cylinder assembly.
13. REMOVE PARKING BRAKE SHOE ADJUSTING HOLE PLUG
(a) Remove the parking brake shoe adjusting hole plug.
14. 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 and press firmly the shoe adjuster until the wheel comes free.
REASSEMBLY
1. INSTALL REAR DISC
(a) Aligning the matchmarks, install the rear disc.
NOTICE: When replacing the rear disc with a new one, select the installation position where the rear disc has the minimum runout.
2. ADJUST PARKING BRAKE SHOE CLEARANCE
HINT: Hold the rear disc with hub nuts by the parking brake pedal (or lever) before adjusting the parking brake shoe clearance.
3. INSTALL PARKING BRAKE SHOE ADJUSTING HOLE PLUG
(a) Install the parking brake shoe adjusting hole plug.
4. TEMPORARILY TIGHTEN REAR DISC BRAKE BLEEDER PLUG
(a) Temporarily install the rear disc brake bleeder plug to the rear disc brake cylinder assembly.
5. INSTALL REAR DISC BRAKE BLEEDER PLUG CAP
(a) Install the rear disc brake bleeder plug cap to the rear disc brake bleeder plug.
6. INSTALL PISTON SEAL
(a) Apply lithium soap base glycol grease to a new piston seal.
(b) Install the piston seal to the rear disc brake cylinder sub-assembly.
7. INSTALL REAR DISC BRAKE PISTON
(a) Apply lithium soap base glycol grease to the rear disc brake piston and a new cylinder boot.
(b) Install the cylinder boot to the rear disc brake piston.
(c) Install the rear disc brake piston to the rear disc brake cylinder assembly.
NOTICE: Do not install the rear disc piston forcibly in the rear disc brake cylinder assembly.
8. INSTALL CYLINDER BOOT
(a) Install the cylinder boot to the rear disc brake cylinder assembly.
NOTICE:
^ Install the boot securely onto the grooves of the cylinder and the piston.
^ Do not damage the cylinder boot.
(b) Using a screwdriver, install the brake cylinder boot set ring.
CAUTION: Be careful not to damage the cylinder boot.
HINT: Tape the screwdriver tip before using.
9. INSTALL REAR DISC BRAKE BUSHING DUST BOOT
(a) Apply lithium soap base glycol grease to the seal surface of 2 new rear disc brake bushing dust boots.
(b) Install the 2 rear disc brake bushing dust boots to the rear disc brake cylinder mounting.
10. INSTALL REAR DISC BRAKE CYLINDER SLIDE PIN
(a) Apply the lithium soap base glycol grease to the sliding part and the seal surface of the rear disc brake cylinder slide pin.
(b) Install the 2 rear disc brake cylinder slide pins (upper and lower) to the rear brake cylinder mounting.
11. INSTALL REAR DISC BRAKE CYLINDER MOUNTING
(a) Install the rear disc brake cylinder mounting with the 2 bolts.
Torque: 62 N*m (632 kgf*cm, 46 ft.*lbf)
12. INSTALL NO. 1 REAR DISC BRAKE PAD SUPPORT PLATE
(a) Install the No. 1 rear disc brake pad support plate to the rear disc brake cylinder mounting.
13. INSTALL NO. 2 REAR DISC BRAKE PAD SUPPORT PLATE
(a) Install the No. 2 rear disc brake pad support plate to the rear disc brake cylinder mounting.
14. INSTALL REAR ANTI-SQUEAL SHIM KIT
(a) Apply disc brake grease to the inside of the 2 rear anti-squeal shims and install them and the 2 pad wear indicators to each of the 2 brake pads.
NOTICE:
^ When replacing worn pads, the rear anti-squeal shims must be replaced together with the pads.
^ Apply disc brake grease to the area that contacts the rear anti-squeal shim.
^ Disc brake grease can come out slightly from the area where the rear anti-squeal shim is installed.
^ Make sure that disc brake grease is not applied onto the lining surface.
(b) Install the 2 rear anti-squeal shims and the pad wear indicators to each of the 2 rear brake pads.
NOTICE: Install the pad wear indicator and rear anti-squeal shim in the correct positions and directions.
15. INSTALL REAR BRAKE PAD
(a) Install the 2 rear brake pads with rear anti-squeal shims to the rear disc brake cylinder mounting.