Brakes - Increase In Brake Pedal Travel Over Time

T-SB-0235-12

December 5, 2012

Rear Brake Strut Improvement

Service Category
Brake

Section
Brake (rear)

Market
USA





Applicability

Introduction

Some 2009 - 2013 Japan-built Corolla vehicles may exhibit a condition where, over time, there is a slight, but perceptible increase in brake pedal travel. This condition has no effect on braking performance. Improved rear drum brake adjusters have been developed to address this condition.

Production Change Information





This bulletin applies to vehicles produced BEFORE the Production Change Effective VIN shown.





Warranty Information





Parts Information





Required Tools & Equipment

Repair Procedure

1. Test-drive the vehicle and confirm the condition.

2. Remove rear wheels.

3. Remove the rear drums.

A. Disengage the parking brake.

B. Remove the rear drum.

NOTE

If the rear drum cannot be removed easily complete steps 4 and 5, otherwise continue to step 6.





4. Remove the shoe adjusting hole plug and insert a screwdriver through the hole into the backing plate and hold the automatic adjust lever away from the adjuster.

5. Using another screwdriver, compress the brake shoe by turning the adjusting bolt.

6. Remove the brake shoe (forward leading).





A. Using the SST separate the shoe return spring from the rear brake shoe.

SST: 09921-00010





B. Using the SST remove the 2 shoe hold down spring cups shoe hold down spring pin and the rear brake shoe.

SST: 09718-00010





C. Remove the tension spring to the front brake shoe and rear brake shoe.

7. Remove the rear brake strut set.





A. Remove the shoe return spring from the rear brake shoe and remove the rear brake shoe strut set.





B. Using needle-nose pliers separate the parking brake cable.





8. Remove the forward leading rear brake shoes from the backing plate.

9. Install the rear brake shoes with the NEW strut set.





A. Apply high temperature grease to the surface of the backing plate that contacts the forward leading brake shoe as indicated.





B. Using needle-nose pliers, install the parking brake cable to the rear brake parking brake shoe lever assembly.





C. Using the SST install the rear brake shoe pin and hold down spring cup.

SST: 09718-00010





D. Apply high temperature grease to the NEW adjustment bolt (strut set).





E. Install the rear brake strut set assembly with tension spring.

10. Install rear brake shoe (forward leading).





A. Using the SST, Install the rear brake shoe, pin and hold down spring and shoe hold down spring cup.

SST: 09921-00010





B. Using needle-nose pliers install the tension spring to the rear brake shoe.





C. Using the SST install the shoe return spring to the rear brake shoe.

SST: 09921-00010

11. Inspect rear drum brake.





A. Inspect that each part is installed properly as shown in the illustration.





B. Measure the brake drum inner diameter and the diameter of the brake shoes. Check that the difference between the diameters is equal to the specified shoe clearance.

Shoe clearance: 0.4 mm (0.0157 in.)

C. Install rear brake drum(s).

12. Adjust parking brake lever travel.





A. Remove the upper console box assembly.

Using a plastic pry tool, disengage the 6 clips and 2 guides, and remove the upper console panel sub-assembly.

B. Completely release the parking brake lever.





C. Loosen the lock nut and the adjusting nut to completely release the cable.

D. Operate the brake lever 3 to 5 times with the engine stopped.

E. Turn the adjusting nut until the parking brake lever travel is corrected to within the specified range.

Parking Brake Lever Travel: 6 to 9 notches at 200 N*m (20 kgf*cm, 45.0 ft*lbf)

F. Using a wrench or an equivalent tool, hold the adjusting nut and tighten the lock nut.

Torque: 6.0 N*m (61 kgf*cm, 53 in*lbf)

G. Operate the parking brake lever 3 to 4 times, and check the parking brake lever travel.

H. Check for any rear brake drag and adjust as needed.





I. Install the upper console box assembly by engaging the 6 clips and 2 guides.

13. Install the rear wheels and torque to specification.

Torque: 103 N*m (1050 kgf*cm, 76 ft*lbf)

14. Test-drive the vehicle and confirm proper brake operation and pedal feel.

© 2012 Toyota Motor Sales, USA