Parking Brake ASSY: Overhaul

HINT:

Use the same procedures for the RH side and LH side.
The procedures listed below are for the LH side.

REMOVE REAR WHEEL
SEPARATE REAR DISC BRAKE CALIPER ASSY LH
1. Remove the 2 bolts and separate the rear disc brake caliper assy LH.
  HINT:
  
  Do not disconnect the flexible hose from the disc brake caliper assy LH.
  
  Fig 1: Separating Rear Disc Brake Caliper Assy LH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DISC
1. Release the parking brake.
2. Put matchmarks on the rear disc and the axle hub.
  
  Fig 2: Putting Matchmarks On Rear Disc And Axle Hub
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the rear disc.
  HINT:
  
  If the disc cannot be removed easily, turn the shoe adjuster until the wheel turns freely.
  
  Fig 3: Removing Rear Disc
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT BRAKE DISC INSIDE DIAMETER
1. Using a brake drum gauge or equivalent tool, measure the inside diameter of the rear disc.
  Standard inside diameter: 170 mm (6.69 in.)
  
  Maximum inside diameter: 171 mm (6.73 in.)
  
  If the inside diameter exceeds the maximum, replace the brake disc.
  
  Fig 4: Inspecting Brake Disc Inside Diameter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE PARKING BRAKE SHOE RETURN TENSION SPRING
1. Using needle-nose pliers, remove the 2 return tension springs No.1.
  
  Fig 5: Removing Return Tension Springs Using Needle-Nose Pliers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE PARKING BRAKE SHOE STRUT LH
1. Remove the parking brake shoe strut LH and strut compression spring.
REMOVE PARKING BRAKE SHOE
1. Release the spring cup claw and remove the parking brake shoe assy LH No.2 and No.1.
2. Disconnect the parking brake cable assy No.3 from the shoe lever.
3. Remove the return tension spring No.2 and adjusting screw set from the parking brake shoe assy LH No.2 and No.1.
4. Remove the 2 hold down compression springs, 4 hold down spring cups and 2 hold down spring pins.
5. Using a screwdriver, remove the C-washer.
6. Remove the shim and shoe lever from the parking brake shoe assy LH No.2.
  
  Fig 6: Removing Shim And Shoe Lever From Parking Brake Shoe Assy LH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Fig 7: Removing C-Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT PARKING BRAKE SHOE LINING THICKNESS
1. Using a ruler, measure the thickness of the shoe lining.
  Standard thickness: 2.0 mm (0.079 in.)
  
  Minimum thickness: 1.0 mm (0.039 in.)
  
  If the lining thickness is less than the minimum, or if there is severe or uneven wear, replace the brake shoe.
  
  NOTE: Replace both the right and left parking brake shoes as a set.
  
  Fig 8: Inspecting Parking Brake Shoe Lining Thickness
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT BRAKE DISC AND PARKING BRAKE SHOE LINING FOR PROPER CONTACT
1. Apply chalk to the inside surface of the disc, then grind down the brake shoe lining to fit the disc.
  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.
  
  Fig 9: Inspecting Brake Disc And Parking Brake Shoe Lining For Proper Contact
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
APPLY HIGH TEMPERATURE GREASE
1. Apply high temperature grease to the backing plate which makes contact with the shoe (see COMPONENTS ).

INSTALL PARKING BRAKE SHOE

Install the shoe lever and shim to the parking brake shoe assy LH No.2 with a new C-washer.

Using a feeler gauge, measure the clearance.

Standard clearance: Less than 0.35 mm (0.0138 in.)

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

SHIM THICKNESS SPECIFICATION

Shim Thickness	Shim Thickness
0.3 mm (0.012 in.)	0.9 mm (0.035 in.)
0.6 mm (0.024 in.)	-

Fig 10: Measuring Clearance Using Feeler Gauge

Apply high temperature grease to the adjusting screw set.
Install the adjusting screw set and return tension spring No.2 to the parking brake shoe assy LH No.1 and No.2.
Install the 2 hold down spring pins, 4 hold down spring cups and 2 hold down compression springs.
Connect the parking brake cable assy No.3 to the shoe lever.
Install the parking brake shoe assy LH No.1 and No.2.

Fig 11: Installing Parking Brake Shoe Assy LH
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL PARKING BRAKE SHOE STRUT LH
1. Attach the parking brake shoe strut LH and strut compression spring to the parking brake shoe assy LH No.2 and No.1.
INSTALL PARKING BRAKE SHOE RETURN TENSION SPRING
1. Using needle-nose pliers, install the 2 return tension springs No.1.
  HINT:
  
  Install the front side spring before the rear side spring.
  
  Fig 12: Installing Parking Brake Shoe Return Tension Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CHECK PARKING BRAKE INSTALLATION
1. Check that each part is installed properly.
  NOTE: There should be no oil or grease adhering to the friction surface of the shoe lining and disc.
  
  Fig 13: Checking Parking Brake Installation
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR DISC
1. Align the matchmarks and install the rear disc.
  
  Fig 14: Installing Rear Disc
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
ADJUST PARKING BRAKE SHOE CLEARANCE
1. Temporarily install the hub nuts.
2. Remove the hole plug, turn the adjuster and expand the shoes until the disc locks.
3. Contract the shoe adjuster until the disc rotates smoothly.
  Standard: Return 8 notches
4. Check that there is no brake drag against the shoe.
5. Install the hole plug.
  
  Fig 15: Installing Hole Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR DISC BRAKE CALIPER ASSY LH
1. Install the rear disc brake caliper assy LH with the 2 bolts.
  Torque: 62 N.m (630 kgf.cm, 46 ft.lbf)
  
  Fig 16: Installing Rear Disc Brake Caliper Assy LH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR WHEEL
Torque: 103 N.m (1,050 kgf.cm, 76 ft.lbf)
INSPECT AND ADJUST PARKING BRAKE PEDAL TRAVEL (SEE ADJUSTMENT )