Parking Brake System: Service and Repair

PARKING BRAKE ASSEMBLY

Parking Brake Assembly Components:

DISASSEMBLY
1. REMOVE REAR WHEEL
Torque: 110 Nm (1122 kgf-cm, 81 ft. lbs.)

2. REMOVE REAR DISC BRAKE CYLINDER ASSEMBLY





a) Remove the 2 mounting bolts and remove the disc brake assembly.
Torque: 105 Nm (1070 kgf-cm, 77 ft. lbs.)
b) Suspend the disc brake securely and so the hose is not stretched.

3. REMOVE REAR DISC





a) Release the parking brake lever.
b) Place matchmarks on the disc and rear axle hub.
c) Remove the disc.

HINT:
^ If the disc cannot be removed easily, turn the shoe adjuster until the wheel turns freely.
^ If there are no matchmarks, temporarily install the disc, then measure the disc runout and install the disc in position.

4. REMOVE PARKING BRAKE SHOE RETURN REAR TENSION SPRING





a) Using needle-nose pliers, remove the 2 shoe return springs.

5. REMOVE PARKING BRAKE SHOE STRUT WITH SPRING

HINT: At the time of reassembly, install the strut with the spring facing forward.

6. ADJUST PARKING BRAKE SHOE ADJUSTING SCREW
a) Slide the front shoe toward outside, remove the shoe adjuster.

7. REMOVE PARKING BRAKE SHOE NO. 1
a) Using a needle-nose pliers, disconnect the anchor spring and tension spring from the front shoe.
b) Remove the anchor spring and tension spring.





c) Using a clip remover, remove the front shoe with holding the cup.

HINT: At the time of reassembly, hold the cup with clip remover. In this condition, install the front shoe.

d) Remove the 2 cups, shoe hold-down spring and pin.

8. REMOVE PARKING BRAKE SHOE NO.2





a) Using a clip remover, remove the rear shoe with holding the cup.

HINT: At the time of reassembly, hold the cup with clip remover. In this condition, install the rear shoe.

b) Remove the 2 cups, shoe hold-down spring and pin.





c) Disconnect the parking brake cable from the parking brake shoe lever.

INSPECTION
1. INSPECT DISASSEMBLED PARTS
a) Inspect the disassembled parts for wear, rust or damage.

2. INSPECT BRAKE SHOE LINING THICKNESS





a) Using a ruler, measure the thickness of the shoe lining.
Standard thickness: 4.0 mm (0.157 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 and uneven wear, replace the brake shoe.

3. INSPECT BRAKE DRUM INSIDE DIAMETER





a) Using a brake drum gauge or equivalent, measure the inside diameter of the disc.
Standard inside diameter: 210 mm (8.27 inch)
Maximum inside diameter: 211 mm (8.31 inch)
b) Replace the disc if the inside diameter is at the maximum value or more.
c) Replace the disc or grind it with a lathe if the disc is scored or worn unevenly.

4. INSPECT PARKING BRAKE SHOE LINING AND DISC FOR PROPER CONTACT





a) 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. INSPECT CLEARANCE BETWEEN PARKING BRAKE SHOE AND LEVER








a) Using a feeler gauge, measure the clearance.
Standard clearance: Less than 0.25 mm (0.010 inch)
If the clearance is not within the specification, replace the shim with one of the correct size.

6. REPLACE PARKING BRAKE SHOE SHIM





a) Using a screwdriver, remove the C-washer and shim.
b) Install the correct size shim with a new C-washer.
c) Remeasure the clearance.

REASSEMBLY
Reassembly is in the reverse order of disassembly.

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

1. ADJUST PARKING BRAKE SHOE CLEARANCE





a) Temporarily install the 3 hub nuts.
b) Turn the adjuster and expand the shoes until the disc locks.
c) Return the adjuster 8 notches.

2. SETTLE PARKING BRAKE SHOE AND REAR DISC
a) Depress the parking brake pedal with 147 N (15 kgf, 33 ft. lbs.).
b) Drive the vehicle at about 50 km/h (31 mph) on a safe, level and dry road for about 400 meters (0.25 mile) in this condition.
c) Repeat this procedure 2 or 3 times.

3. CHECK AND ADJUST PARKING BRAKE LEVER TRAVEL