Rear Brake Shoe, Wheel Cylinder & Brake Drum (NUMMI/TMMC Made): Overhaul

HINT:

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

1. REMOVE REAR WHEEL 
2. DRAIN BRAKE FLUID 
   NOTE: Wash brake fluid off immediately if it adheres to any painted surface.
3. REMOVE REAR BRAKE DRUM SUB-ASSY 
   1. Put matchmarks on the rear brake drum sub-assy and the axle hub.
   2. Release the parking brake and remove the rear brake drum sub-assy.

      HINT:

      If the brake drum cannot be removed easily, do the following steps.

      Fig 1: Putting Matchmarks On Rear Brake Drum Sub-Assy And Axle Hub

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Remove the hole plug and insert a screwdriver through the hole in the backing plate, and hold the automatic adjusting lever away from the adjuster.
   4. Using another screwdriver, contract the brake shoe adjuster by turning the adjusting bolt.
   Fig 2: Inserting Screwdriver Through Hole In Backing Plate

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. INSPECT BRAKE DRUM INSIDE DIAMETER 
   1. Using a brake drum gauge or equivalent, measure the inside diameter of the drum.

      Standard inside diameter: 200.0 mm (7.874 in.) 

      Maximum inside diameter: 201.0 mm (7.913 in.) 

      HINT:

      If the inside diameter of the brake drum is at the maximum or more, replace the brake drum sub-assy.

      Fig 3: Measuring Inside Diameter Of Drum

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. REMOVE REAR BRAKE AUTOMATIC ADJUST LEVER LH 
   1. Using needle-nose pliers, remove the upper side tension spring.
   2. Remove the rear brake automatic adjust lever LH from the rear brake shoe.
   Fig 4: Removing Rear Brake Automatic Adjust Lever LH

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. REMOVE FRONT BRAKE SHOE 
   1. Using needle-nose pliers, remove the anchor side tension spring.
      Fig 5: Removing Anchor Side Tension Spring

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Using SST, remove the cup, shoe hold-down spring and pin.

      SST 09718-00010

   3. Separate the upper side return spring from the front brake shoe, and remove the front brake shoe.
   Fig 6: Removing Cup, Shoe Hold-Down Spring And Pin

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. REMOVE PARKING BRAKE SHOE STRUT SET LH 
8. REMOVE REAR BRAKE SHOE 
   1. Using SST, remove the cup, shoe hold-down spring and pin.

      SST 09718-00010

      Fig 7: Removing Cup, Shoe Hold-Down Spring And Pin

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Using needle-nose pliers, separate the parking brake cable No.3 and remove the rear brake shoe.
   3. Remove the upper side return spring from the rear brake shoe.
   Fig 8: Removing Rear Brake Shoe

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. REMOVE REAR BRAKE PARKING BRAKE SHOE LEVER SUB-ASSY 
   1. Using a screwdriver, remove the C-washer and parking brake shoe lever sub-assy.
   Fig 9: Removing C-Washer And Parking Brake Shoe Lever Sub-Assy Using Special Tool

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. INSPECT REAR DRUM BRAKE SHOE LINING THICKNESS 
    1. Using a ruler, measure the thickness of the shoe lining.

       Standard thickness: 4.0 mm (0.157 in.) 

       Minimum thickness: 1.0 mm (0.039 in.) 

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

    Fig 10: Measuring Thickness Of Shoe Lining

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. INSPECT BRAKE DRUM AND REAR DRUM BRAKE SHOE LINING FOR PROPER CONTACT 
    1. Apply chalk to the inside surface of the drum, then grind drum on the brake shoe lining to fit.

       If the contact between the drum and the shoe lining is improper, repair it using a brake shoe grinder or replace the brake shoe assembly.

    Fig 11: Applying Chalk To Inside Surface Of Drum

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. REMOVE REAR WHEEL BRAKE CYLINDER ASSY 
    1. Using SST, disconnect the brake line.

       SST 09023-00101

       HINT:

       Use a container to catch the brake fluid.

    2. Remove the bolt and the wheel brake cylinder assy.
    Fig 12: Disconnecting Brake Line Using Special Tool

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
13. REMOVE REAR WHEEL CYLINDER CUP KIT 
    1. Remove the 2 cylinder dust boots from the wheel brake cylinder.
    2. Remove the 2 pistons and compression spring.
    3. Remove the 2 wheel cylinder cups from each piston.
    4. Remove the bleeder plug cap and bleeder plug from the wheel brake cylinder.
14. INSPECT BRAKE WHEEL CYLINDER 
    1. Check the cylinder bore and the piston for rust or scoring.

       If necessary, replace the wheel brake cylinder assy.

15. INSTALL REAR WHEEL CYLINDER CUP KIT 
    1. Temporarily tighten the bleeder plug to the wheel brake cylinder assy, and install the bleeder plug cap.
    2. Apply the lithium soap base glycol grease to 2 new wheel cylinder cups and 2 pistons.
    3. Install the 2 wheel cylinder cups on each piston.
    4. Install the compression spring and the 2 pistons to the wheel brake cylinder assy.
    5. Install 2 new cylinder dust boots to the wheel brake cylinder assy.
    Fig 13: Installing Rear Wheel Cylinder Cup Kit

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
16. INSTALL REAR WHEEL BRAKE CYLINDER ASSY 
    1. Install the wheel brake cylinder assy with the bolt.

       Torque: 10 N.m (102 kgf.cm, 7 ft.lbf) 

    2. Using SST, connect the brake tube.

       SST 09023-00101

       Torque: 15 N.m (155 kgf.cm, 11 ft.lbf) 

       Fig 14: Connecting Brake Tube Using Special Tool

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
17. APPLY HIGH TEMPERATURE GREASE 
    1. Apply high temperature grease to the shoe attached surface of the backing plate.
    Fig 15: Applying High Temperature Grease To Shoe Attached Surface Of Backing Plate

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
18. INSTALL REAR BRAKE PARKING BRAKE SHOE LEVER SUB-ASSY 
    1. Using pliers, install the parking brake shoe lever sub-assy with a new C-washer.
    Fig 16: Installing Parking Brake Shoe Lever Sub-Assy With C-Washer Using Special Tool

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
19. INSTALL REAR BRAKE SHOE 
    1. Using needle-nose pliers, connect the parking brake cable No.3 to the parking brake shoe lever sub-assy.
       Fig 17: Connecting Parking Brake Cable No.3 To Parking Brake Shoe Lever Sub-Assy Using Special Tool

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, install the rear brake shoe, the pin, the shoe hold down spring and the shoe hold down cup.

       SST 09718-00010

    3. Connect the upper side return spring to the rear brake shoe.
    Fig 18: Connecting Upper Side Return Spring To Rear Brake Shoe

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
20. INSTALL PARKING BRAKE SHOE STRUT SET LH 
    1. Apply the high temperature grease to the adjusting bolt.
    2. Install the parking brake shoe strut set to the rear brake shoe.
21. INSTALL FRONT BRAKE SHOE 
    1. Install the upper side return spring to the front brake shoe.
       Fig 19: Installing Upper Side Return Spring To Front Brake Shoe

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, install the front brake shoe, the pin, the shoe hold down spring and the cup.

       SST 09718-00010

       Fig 20: Installing Front Brake Shoe, Pin, Shoe Hold Down Spring And Cup Using Special Tool

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using needle-nose pliers, install the anchor side tension spring to each shoe.
22. INSTALL REAR BRAKE AUTOMATIC ADJUST LEVER LH 
    1. Install the automatic adjust lever to the rear brake shoe.
       Fig 21: Installing Automatic Adjust Lever To Rear Brake Shoe

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using needle-nose pliers, install the upper side tension spring.
    Fig 22: Installing Upper Side Tension Spring Using Special Tool

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
23. CHECK REAR DRUM BRAKE INSTALLATION 
    1. Check that each part is installed properly.
    NOTE: There should be no oil or grease adhering to the friction surfaces of the shoe lining and drum.

    If they are not installed correctly, reinstall them as shown in the illustration.

    Fig 23: Checking Rear Drum Brake Installation

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
24. INSTALL REAR BRAKE DRUM SUB-ASSY 
    1. Aligning the matchmarks, install the rear brake drum sub-assy.
25. ADJUST REAR DRUM BRAKE SHOE CLEARANCE 
    1. Temporarily install the hub nuts.
    2. Remove the hole plug, and turn the adjuster and expand the adjuster until the drum locks.
       Fig 24: Removing Hole Plug

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a screwdriver, back off the adjuster 8 notches.
    4. Install the hole plug.
    Fig 25: Installing Hole Plug Using Special Tool

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
26. FILL RESERVOIR WITH BRAKE FLUID (see  BRAKE FLUID  ) 
27. BLEED MASTER CYLINDER (see  BRAKE FLUID  ) 

    SST 09023-00101

28. BLEED BRAKE LINE (see  BRAKE FLUID  ) 
29. CHECK FLUID LEVEL IN RESERVOIR (see  BRAKE FLUID  ) 
30. CHECK FOR BRAKE FLUID LEAKAGE 
31. INSTALL REAR WHEEL 

    Torque: 103 N.m (1,050 kgf.cm, 76 ft.lbf) 

32. INSPECT PARKING BRAKE LEVER TRAVEL (see  ADJUSTMENT  ) 
33. ADJUSTMENT PARKING BRAKE LEVER TRAVEL (see  ADJUSTMENT  )