Rear

REAR BRAKE
OVERHAUL

HINT: Overhaul the RH side by the same procedures with LH side.

1. REMOVE REAR WHEEL
2. DRAIN BRAKE FLUID

NOTICE: Do not let brake fluid remain on a painted surface. Wash it off immediately.

3. SEPARATE REAR LH FLEXIBLE HOSE
a. Remove the union bolt and gasket from the disc brake cylinder, then disconnect the flexible hose fro the disc brake cylinder.

HINT: Gasket has 2 types: 2-piece type and 1-piece type.

4. REMOVE REAR DISC BRAKE CYLINDER SLIDE PIN
5. REMOVE DISC BRAKE CYLINDER ASSY REAR LH
a. Lift up the disc brake cylinder and remove the disc brake cylinder.
6. REMOVE REAR DISC BRAKE BUSH DUST BOOT
7. REMOVE FRONT DISC BRAKE CYLINDER SLIDE PIN
a. Using a hexagon wrench (8 mm), remove the cylinder slide pin.
8. REMOVE DISC BRAKE PAD KIT REAR (PAD ONLY)
a. Remove the 2 brake pads with anti-squeal shim.
9. REMOVE REAR DISC BRAKE ANTI SQUEAL SHIM KIT
a. Remove the anti squeal shim and pad wear indicator from each of 2 brake pads.
10. REMOVE REAR DISC BRAKE PAD SUPPORT PLATE
11. REMOVE REAR DISC BRAKE PAD SUPPORT PLATE
12. REMOVE REAR DISC BRAKE CYLINDER SLIDE BUSH
13. REMOVE REAR DISC BRAKE CYLINDER MOUNTING LH
a. Remove the 2 bolts and cylinder mounting LH.
14. REMOVE CYLINDER BOOT
a. Using a screwdriver, remove the set ring and cylinder boot.





15. REMOVE REAR DISC BRAKE DISC BRAKE PISTON
a. Place a piece of cloth or similar, 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.

16. 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.

17. REMOVE REAR DISC BRAKE BLEEDER PLUG CAP
18. REMOVE REAR DISC BRAKE BLEEDER PLUG
19. INSPECT BRAKE CYLINDER AND PISTON
a. Check the cylinder bore and piston for rust or scoring.
20. INSPECT PAD LINING THICKNESS
a. Using a ruler, measure the pad lining thickness.
Standard thickness: 11.0 mm (0.433 inch)
Minimum thickness: 1.0 mm (0.039 inch)
21. INSPECT DISC THICKNESS
a. Using a micrometer, measure the disc thickness.
Standard thickness: 10.0 mm (0.394 inch)
Minimum thickness: 8.5 mm (0.335 inch)
22. REMOVE REAR DISC
a. Put matchmarks; on the disc and the axle hub.
b. Remove the disc.
23. INSTALL REAR DISC
a. Aligning the matchmarks, install the rear disc.

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





24. INSPECT DISC RUNOUT
a. Temporarily fasten the disc with hub nuts.
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
b. Using dial indicator, measure the disc runout 10 mm (0.39 inch) away from the outer edge of the disc.
Maximum disc runout: 0.15 mm (0.0059 inch)
c. If the disc's runout is maximum value or greater, check the bearing play in the axial direction and check the axle hub runout. If the bearing play and axle hub runout are not abnormal, adjust the disc runout or grind it on a "On-car" brake lathe.
25. ADJUST PARKING BRAKE SHOE CLEARANCE
26. TEMPORARY 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 the lithium soap base glycol grease on a new piston seal.
b. Install the piston seal to the disc brake cylinder.
29. INSTALL REAR DISC BRAKE DISC BRAKE PISTON
a. Apply the lithium soap base glycol grease on the piston.
b. Install the piston to the disc brake cylinder smoothly.
30. INSTALL CYLINDER BOOT
a. Apply the lithium soap base glycol grease on a new cylinder boot.
b. Install the cylinder boot to the disc brake cylinder.

HINT: Install the boot securely to the grooves of the cylinder and piston.

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:
4WD: 58 Nm (590 kgf-cm, 43 ft. lbs.)
2WD: 62 Nm (605 kgf-cm, 44 ft. lbs.)





32. INSTALL REAR DISC BRAKE CYLINDER SLIDE BUSH
a. Apply the lithium soap base glycol grease on a new cylinder slide bush.
b. Install the cylinder slide bush.
33. INSTALL REAR DISC BRAKE PAD SUPPORT PLATE
34. INSTALL REAR DISC BRAKE PAD SUPPORT PLATE
35. INSTALL REAR DISC BRAKE ANTI SQUEAL SHIM KIT

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

a. Apply disc brake grease to inside of anti-squeal shims, and install the anti-squeal shim and pad wear indicator plate each of 2 brake pads.
36. INSTALL DISC BRAKE PAD KIT REAR (PAD ONLY)

NOTICE: There should be no oil or grease adhering to the friction surface of the pads and the disc.

37. INSTALL REAR DISC BRAKE CYLINDER SLIDE PIN
a. Using a hexagon wrench (8 mm), install the cylinder side pin.
Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.)
b. Apply the lithium soap base glycol grease to the cylinder slide pin.





38. INSTALL REAR DISC BRAKE BUSH DUST BOOT
a. Apply the lithium soap base glycol grease to seal surface of a new bush dust boot.
b. Install the bush dust boot to the cylinder slide pin.
39. INSTALL DISC BRAKE CYLINDER ASSY REAR LH
40. INSTALL REAR DISC BRAKE CYLINDER SLIDE PIN
a. Install the cylinder slide pin.
Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.)
41. CONNECT REAR LH FLEXIBLE HOSE
a. Connect a new gasket and flexible hose with the union bolt.
Torque: 29 Nm (300 kgf-cm, 21 ft. lbs.)
42. FILL RESERVOIR WITH BRAKE FLUID
43. BLEED MASTER CYLINDER
44. BLEED BRAKE LINE
45. CHECK FLUID LEVEL IN RESERVOIR
46. CHECK BRAKE FLUID LEAKAGE
47. INSTALL REAR WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)