Rear Brake Shoe, Wheel Cylinder & Brake Drum: Overhaul

HINT:

• Overhaul the RH side using the same procedures as those for the LH side.
• If work that does not involve brake fluid bleeding, such as drum brake shoe replacement, is started 2 minutes or more after the power switch is turned off, brake control (ECB) prohibition is not necessary.

1. REMOVE REAR WHEEL 
2. BRAKE CONTROL (ECB) OFF (See  REPLACEMENT   ) 
   NOTE: Prohibit the brake control (ECB) certainly before bleeding the brake fluid  .
3. DRAIN BRAKE FLUID 
   NOTE: Wash brake fluid off immediately if it adheres to any painted surfaces. 
4. REMOVE REAR BRAKE DRUM SUB-ASSY 
   1. Put matchmarks on the rear brake drum and the axle hub.
   2. Release the parking brake and remove the rear brake drum sub-assy.

   HINT:

   If the rear brake drum sub-assy cannot be removed, push the rear brake automatic adjust lever through the backing plate service hole using a screwdriver. Turn and contract the adjuster using another screwdriver.

   Fig 1: Removing Rear Brake Drum Sub-Assy

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. 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 2: Inspecting Brake Drum Inside Diameter

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

      SST 09703-30011

   NOTE: Be careful not to damage the cylinder dust boot. 
   Fig 3: Separating Parking Brake Shoe Strut Set LH

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

      SST 09718-00010

   2. Remove the brake shoe (front) and tension spring.
   Fig 4: Removing Front Brake Shoe

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. REMOVE PARKING BRAKE SHOE STRUT SET LH 
   1. Remove the parking brake shoe strut set from the brake shoe (rear).
9. REMOVE REAR BRAKE AUTOMATIC ADJUST LEVER LH 
   1. Remove the rear brake automatic adjust lever tension spring and the rear brake automatic adjust lever.
   Fig 5: Removing Rear Brake Automatic Adjust Lever LH

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. REMOVE REAR BRAKE SHOE 
    1. Remove the tension spring from the brake shoe (rear).
    2. Using SST, remove the shoe hold down spring cup, the shoe hold down spring and shoe hold down spring pin.

       SST 09718-00010

       Fig 6: Removing Rear Brake Shoe

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using needle-nose pliers, disconnect the parking brake cable, and remove the brake shoe (rear).
       Fig 7: Disconnecting Parking Brake Cable, And Removing Brake Shoe (Rear)

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. REMOVE REAR BRAKE PARKING BRAKE SHOE LEVER SUB-ASSY 
    1. Using a screwdriver, remove the C-washer and the parking brake shoe lever.
    Fig 8: Removing Rear Brake Parking Brake Shoe Lever Sub-Assy

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. 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 (0.039in.) 

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

    Fig 9: Inspecting Rear Drum Brake Shoe Lining Thickness

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
13. 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 10: Inspecting Brake Drum And Rear Drum Brake Shoe Lining For Proper Contact

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
14. REMOVE LH, FRONT OR UPPER 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 rear wheel brake cylinder assy.
    Fig 11: Removing Bolt And Rear Wheel Brake Cylinder Assy

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

    If necessary, replace the brake wheel cylinder sub-assy.

17. REMOVE DRUM BRAKE, REAR BLEEDER PLUG 
    1. Remove the rear drum bleeder plug from the rear wheel cylinder assy.
18. TEMPORARILY TIGHTEN DRUM BRAKE, REAR BLEEDER PLUG 
    1. Install the rear drum brake bleeder plug to the rear wheel cylinder assy.
19. 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 rear wheel brake cylinder.
    4. Install the 2 new cylinder dust boots to the rear wheel brake cylinder.
    Fig 12: Installing Rear Wheel Cylinder Cup Kit

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
20. INSTALL LH, FRONT OR UPPER REAR WHEEL BRAKE CYLINDER ASSY 
    1. Install the rear 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 13: Installing LH, Front Or Upper Rear Wheel Brake Cylinder Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
21. APPLICATION HIGH TEMPERATURE GREASE 
    1. Apply high temperature grease to the shoe attached surface of the backing plate.
    Fig 14: Applying High Temperature Grease

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
22. INSTALL REAR BRAKE PARKING BRAKE SHOE LEVER SUB-ASSY 
    1. Using needle-nose pliers, install the parking brake lever with a new C-washer.
    Fig 15: Installing Rear Brake Parking Brake Shoe Lever Sub-Assy

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
23. INSTALL REAR BRAKE SHOE 
    1. Using needle-nose pliers, connect the parking brake cable No.3 to the parking brake shoe lever.
       Fig 16: Installing Rear Brake Shoe

       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

    Fig 17: Installing Rear Brake Shoe

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
24. INSTALL REAR BRAKE SHOE RETURN SPRING 
    1. Install the rear brake shoe return spring to the brake shoe (rear).
25. INSTALL REAR BRAKE AUTOMATIC ADJUST LEVER LH 
    1. Install the rear brake automatic adjust lever and the rear brake automatic adjust lever tension spring to the front brake shoe.
    Fig 18: Installing Rear Brake Automatic Adjust Lever LH

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
26. 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 19: Installing Parking Brake Shoe Strut Set LH

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the parking brake shoe strut set as shown in the illustration.
       Fig 20: Installing Parking Brake Shoe Strut Set

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
27. INSTALL FRONT BRAKE SHOE 
    1. Connect the tension spring to the brake shoe (front) and rear brake shoe.
    2. Using SST, install the brake shoe (front), the pin, the shoe hold down spring and the cup.

       SST 09718-00010

    Fig 21: Installing Front Brake Shoe

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
28. CONNECT PARKING BRAKE SHOE STRUT SET LH 
    1. Using SST, connect the shoe return spring to the front brake shoe and rear brake shoe.

       SST 09703-30011

    NOTE: Be careful not to damage the wheel cylinder boot. 
    Fig 22: Connecting Parking Brake Shoe Strut Set LH

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
29. 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 as shown in the illustration, reinstall them.

       Fig 23: Checking Rear Drum Brake Installation

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Measure the brake drum inside diameter and the diameter of the brake shoes. Check the difference between the diameters the correct shoe clearance.

       Shoe clearance: 0.6 mm (0.024 in.) 

    NOTE: There should be no oil or grease adhering to the friction surfaces of the shoe lining and the drum. 
    Fig 24: Checking Difference Between Diameters Correct Shoe Clearance

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
30. INSTALL REAR BRAKE DRUM SUB-ASSY 
    1. Aligning the matchmarks, install the rear brake drum sub-assy.
31. ADJUST REAR DRUM BRAKE SHOE CLEARANCE 
    1. Temporarily install the 2 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
32. FILL RESERVOIR WITH BRAKE FLUID (See  BRAKE FLUID   ) 
33. BLEED FRONT AND REAR BRAKE SYSTEMS (See  BRAKE FLUID   ) 
34. CHECK BRAKE FLUID LEAKAGE 
35. CHECK FLUID LEVEL IN RESERVOIR 
36. INSTALL REAR WHEEL 

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

37. CHECK PARKING BRAKE PEDAL TRAVEL (See  ADJUSTMENT  ) 
38. ADJUST PARKING BRAKE PEDAL TRAVEL (See  ADJUSTMENT  ) 
39. CHECK AND CLEAR DTC (See  DIAGNOSTIC TROUBLE CODES CHECK/CLEAR  )