Parking Brake System: Service and Repair

DISASSEMBLY
1. Remove rear wheel.




2. Remove rear disc brake assembly.
a. Remove the 2 mounting bolts and remove the disc brake assembly.

Torque: 47 Nm (34 ft. lbs.)

b. Suspend the disc brake securely. Ensure that the hose is not stretched.




3. Remove disc.

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




4. Remove shoe return springs.
Using needle-nose pliers, remove the 2 shoe return springs.
5. Remove shoe strut with spring.




6. Remove front shoe and adjuster.
a. Slide out the front shoe and remove the shoe adjuster.
b. Disconnect the tension spring and remove the front shoe.

7. Remove rear shoe and tension spring.
a. Slide out the rear shoe.
b. Remove the tension spring from the rear shoe.
c. Remove the 4 shoe hold-down spring pins.




d. Using needle-nose pliers, disconnect the parking brake cable from the parking brake shoe lever.

INSPECTION
1. Inspect disassembled parts.
Inspect the disassembled parts for wear, rust or damage.




2. Measure brake shoe lining thickness.
Using a ruler, measure the thickness of the shoe lining.

Standard thickness: 2.0 mm (0.079 inch)
Minimum thickness: 1.0 mm (0.039 inch)

If the lining thickness is at the minimum thickness or less, or if there is severe, uneven wear, replace the brake shoe.




3. Measure disc inside diameter.
Using a vernier calipers, measure the inside diameter of the disc.

Standard inside diameter: 170.0 mm (6.690 inch)
Maximum inside diameter: 171.0 mm (6.732 inch)

Replace the disc if the inside diameter is at the maximum value or more. Replace the disc or grind it with a lathe if the disc is scored or is worn unevenly.




4. Inspect parking brake lining and disc for proper contact.
Apply chalk to the inside surface of the disc, then grind down the brake shoe lining to fit. If the contact between the disc and the brake shoe lining is improper, repair it using a brake shoe grinder or replace the brake shoe assembly.




5. Measure clearance between parking brake shoe and lever.
Using a feeler gauge, measure the clearance.

Standard clearance: Less than 0.35 mm (0.0138 inch)

If the clearance is not within the specification, replace the shim with one of the correct size.

Shim Thickness:
0.3 mm (0.012 inch)
0.6 mm (0.024 inch)
0.9 mm (0.035 inch)




6. If necessary, replace shim.
a. Using a screwdriver, remove the Washer and shim.
b. Install the correct size shim.
c. Install a new washer.
d. Remeasure the clearance.




REASSEMBLY
Reassemble in the reverse order of disassembly.

NOTE: Apply high temperature grease to the parts indicated by the arrows.

1. Adjust parking brake shoe clearance.
a. Temporarily install the hub nuts.
b. Remove the hole plug.




c. Turn the adjuster and expand the shoes until the disc locks.
d. Return the adjuster 8 notches.
e. Install the hole plug.

2. Settling parking brake shoes and disc.
a. Drive the vehicle at about 50 km/h (31 mph) on a safe, level and dry road.
b. With the parking brake release button pushed in, pull on the lever with 98 N (19.8 lbs.) of force.
c. Drive the vehicle for about 400 meters (0.25 mile) in this condition.
d. Repeat this procedure 2 or 3 times.

3. Check and adjust parking brake lever travel.