Rear Brake Shoe, Wheel Cylinder & Brake Drum (TMC 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 Using Special Tool

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. SEPARATE PARKING BRAKE SHOE STRUT SET LH 
   1. Using SST, separate the spring and shoe strut set from the brake shoes.

      SST 09703-30011

   NOTE: Be careful not to damage the cylinder dust boot.
   Fig 4: Removing Spring And Shoe Strut Set From Brake Shoes Using Special Tool

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. REMOVE FRONT BRAKE SHOE 
   1. Using SST, remove the cup, shoe hold-down spring and pin.

      SST 09718-00010

   2. Remove the front brake shoe and tension spring.
   Fig 5: Removing Front Brake Shoe And Tension Spring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. REMOVE PARKING BRAKE SHOE STRUT SET LH 
8. REMOVE AUTOMATIC ADJUST LEVER LH 
   1. Remove the tension spring and the automatic adjust lever.
   Fig 6: Removing Tension Spring And Automatic Adjust Lever

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. 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 Using Special Tool

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

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

       Standard thickness: 4.4 mm (0.173 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 or uneven wear, replace the brake shoe.

    Fig 10: Measuring Thickness Of Shoe Lining Using Special Tool

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. INSPECT BRAKE DRUM AND REAR DRUM BRAKE SHOE LINING FOR PROPER CONTACT 
    1. Apply chalk to the inside surface of the drum, then grind the 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
13. 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: Removing Bolt And Wheel Brake Cylinder Assy

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
14. REMOVE REAR WHEEL CYLINDER CUP KIT 
    1. Remove the 2 cylinder dust boots from the wheel brake cylinder assy.
    2. Remove the 2 pistons and the compression spring.
    3. Remove the 2 wheel cylinder cups from each piston.
15. INSPECT BRAKE WHEEL CYLINDER 
    1. Check the cylinder bore and the piston for rust or scoring. If necessary, replace the brake wheel cylinder assy.
16. REMOVE REAR DRUM BRAKE BLEEDER PLUG 
    1. Remove the bleeder plug from the wheel brake cylinder assy.
17. TEMPORARILY TIGHTEN REAR DRUM BRAKE BLEEDER PLUG 
    1. Install the bleeder plug to the wheel brake cylinder assy.
18. INSTALL REAR WHEEL CYLINDER CUP KIT 
    1. Apply lithium soap base glycol grease to 2 new wheel cylinder cups and 2 pistons.
    2. Install the 2 wheel cylinder cups on each piston.
    3. Install the compression spring and the 2 pistons to the wheel brake cylinder.
    4. Install the 2 new cylinder dust boots to the wheel brake cylinder.
    Fig 13: Installing Cylinder Dust Boots To Wheel Brake Cylinder

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

       Torque: 9.8 N.m (100 kgf.cm, 87 in.lbf) 

    2. Using SST, connect the brake line.

       SST 09023-00101

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

    Fig 14: Connecting Brake Line Using Special Tool

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
20. 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
21. INSTALL PARKING BRAKE SHOE LEVER LH 
    1. Using needle-nose 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
22. 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 brake shoe, the pin, the shoe hold-down spring and the shoe hold-down cup.

       SST 09718-00010

    Fig 18: Installing Brake Shoe, Pin, Shoe Hold-Down Spring And Shoe Hold-Down Cup Using Special Tool

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
23. INSTALL REAR BRAKE SHOE RETURN SPRING 
    1. Install the shoe return spring to the brake shoe.
24. INSTALL AUTOMATIC ADJUST LEVER LH 
    1. Install the automatic adjust lever and the automatic adjust lever tension spring to the front brake shoe.
    Fig 19: Installing Automatic Adjust Lever And Automatic Adjust Lever Tension Spring To Front Brake Shoe

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
25. INSTALL PARKING BRAKE SHOE STRUT SET LH 
    1. Apply high temperature grease to the adjusting bolt and assemble.
    2. Install the shoe return spring to the strut set.
       Fig 20: Installing Shoe Return Spring To Strut Set

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the parking brake shoe strut set as shown in the illustration.
    Fig 21: Installing Parking Brake Shoe Strut Set

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
26. INSTALL FRONT BRAKE SHOE 
    1. Install the tension spring to the brake shoes.
    2. Using SST, install the front brake shoe, the pin, the shoe hold-down spring and the cup.

       SST 09718-00010

    Fig 22: Installing Front Brake Shoe, Pin, Shoe Hold-Down Spring And Cup Using Special Tool

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
27. INSTALL PARKING BRAKE SHOE STRUT SET LH 
    1. Using SST, install the shoe return spring to the brake shoes.

       SST 09703-30011

    NOTE: Be careful not to damage the wheel cylinder boot.
    Fig 23: Installing Shoe Return Spring To Brake Shoes Using Special Tool

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
28. 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 24: Checking Rear Drum Brake Installation

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
29. INSTALL REAR BRAKE DRUM SUB-ASSY 
    1. Aligning the matchmarks, install the rear brake drum sub-assy.
30. ADJUST REAR DRUM BRAKE SHOE CLEARANCE 
    1. Temporarily install the hub nuts.
    2. Remove the hole plug, and turn the adjuster to expand the shoe until the drum locks.
    3. Rotate the adjuster by 8 notches.
    4. Install the hole plug.
    Fig 25: Adjusting Rear Drum Brake Shoe Clearance

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

    SST 09023-00101

33. BLEED BRAKE LINE (see  BRAKE FLUID  ) 
34. CHECK FLUID LEVEL IN RESERVOIR (see  BRAKE FLUID  ) 
35. CHECK FOR BRAKE FLUID LEAKAGE 
36. INSTALL REAR WHEEL 

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

37. INSPECT PARKING BRAKE LEVER TRAVEL (see  ADJUSTMENT  ) 
38. ADJUST PARKING BRAKE LEVER TRAVEL (SEE  ADJUSTMENT  )