BRAKE

SYSTEM
Return To Main Table of Contents
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
BRAKE BOOSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
BRAKE LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
PROPORTIONING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
FRONT DISC BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
REAR DRUM BRAKE (BENDIX). . . . . . . . . . . . . . . . . . . . . . . 25
REAR DRUM BRAKE (MANDO) . . . . . . . . . . . . . . . . . . . . . . 29
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
 GENERAL

GENERAL
GENERAL SPECIFICATIONS

Master cylinder
Type Tandem
I.D. 22.22 mm (0.875 in.)
Fluid level warning sensor Provided
Brake booster
Type Vacuum
Effective dia. 233.1 mm (9.177 in.)
Boosting ratio 4.0 : 1
Proportioning valve
Cut-in pressure (Split point) 3.63 MPa (37 kg/cm2, 526 psi)
Decompression ratio 3.7 : 1
Front brake
Type Floating type with ventilated disc
Disc O.D. 242 mm (9.53 in.)
Disc thickness 19 mm (0.75 in.)
Pad thickness 9 mm (0.354 in.)
Cylinder I.D. 54 mm (2.126 in.)
Rear brake BENDIX MANDO
Type Leading-trailing drum C
Drum I.D. 180 mm (7.1 in.)
Brake lining thickness 4.85 mm (0.19 in.) Leading: 4.5 mm (0.177 in.)
Trailing: 4.6 mm (0.181 in.)
Cylinder I.D. 20.64 mm (0.813 in.) 20.62 mm (0.812 mm)
Clearance adjustment Automatic
Parking brake
Type Mechanical brake acting on rear wheels
Braking type Lever type (cam shape)
Cable arrangement V type

58-2
 GENERAL

SERVICE STANDARD

Standard value
Brake pedal height 163-168 mm (6.417-6.614 in.)
Brake pedal stroke 143 mm (5.63 in.)
Stop light switch outer case to pedal arm clearance 0.5-1.0 mm (0.020-0.040 in.)
Brake pedal free play 10-15 mm (0.394-0.591 in.)
Brake pedal to floorboard clearance 50 mm (1.969 in.) or more
Booster push rod to master cylinder piston clearance 0 (at 500 mmHg vacuum)
Parking brake lever stroke (when lever assembly is 6-7 clicks
pulled with 196 N (20 Kg, 44 lb) force)
Service limit
Front disc brake pad thickness 1.0 mm (0.039 in.)
Front disc thickness (minimum) 17 mm (0.669 in.)
Front disc runout 0.15 mm (0.006 in.)
Drum brake lining thickness 1.0 mm (0.039 in.)
Brake drum I.D. (maximum) 182 mm (7.165 in.)
Wheel cylinder to piston clearance 0.15 mm (0.006 in.)

TIGHTENING TORQUE
Nm kg.cm lb.ft

Master cylinder to booster mounting nut 8-12 80-120 5.8-8.7

Brake booster mounting nut 8-12 80-120 5.8-8.7
Brake booster hose fitting to manifold 8-12 80-120 5.8-8.7
Bleeder screw 7-9 70-90 5.1-6.5
Brake tube flare nut, brake hose 13-17 130-170 9-12
Proportioning valve mounting nut 8-12 80-120 5.8-8.7
Caliper guide rod bolt 22-31 220-320 16-23
Caliper pin bolt 34-44 350-450 25-32
Caliper assembly to knuckle 64-74 650-750 47-54
Brake hose to front caliper 25-30 250-300 18-22
Backing plate mounting bolt 49-59 500-600 36-43
Wheel cylinder mounting bolt 12-18 120-180 8.7-13

58-3
 GENERAL

SPECIAL TOOL

Tool
Illustration Use
(Number and name)

09581-11000 Retraction of the front disc brake piston

Piston expander

58-4
TROUBLESHOOTING

Symptom Probable cause Remedy

Noise or vibration when Backing plate or caliper improperly mounted Correct

brakes are applied
Loose backing plate or caliper mounting bolts Retighten

Unevenly worn or cracked brake drum or brake disc Replace

Foreign material in brake drum Clean

Seized pad or lining contact surface Replace

Excessive caliper to pad assembly clearance Correct

Uneven pad contact Correct

Lack of lubrication in sliding parts Lubricate

Loose suspension parts Retighten

Vehicle pulls to one side Difference in left and right tire inflation pressure Adjust
when brakes are applied
Improper front wheel alignment Adjust

Inadequate contact of pad or lining Correct

Grease or oil on pad or lining surface Replace

Drum eccentricity or uneven wear Replace

Incorrect wheel cylinder installation Correct

Auto adjuster malfunction Correct

Insufficient braking power Low or contaminated brake fluid Replenish or change

Air in brake system Bleed the system

Brake booster malfunction Correct

Inadequate contact of pad or lining Correct

Grease or oil on pad surface Replace

Auto adjuster malfunction Correct

Overheated brake rotor due to dragging of pad Correct

or lining

Restricted brake line Correct

Proportioning valve malfunction Replace

Increased pedal stroke Air in brake system Bleed the system

(Reduced pedal to floorboard
Brake fluid leaks Correct
clearance)
Auto adjuster malfunction Correct

Excessive push rod to master cylinder clearance Adjust

58-5
 Symptom Probable cause Remedy
Brake drag
Incomplete release of parking brake Correct

Incorrect parking brake adjustment Adjust

Weak brake pedal return spring Replace

Restricted master cylinder return port Correct

Broken rear drum brake shoe return spring Replace

Lack of lubrication in sliding parts Lubricate

Insufficient parking
Defective master cylinder check valve or Replace
brake function
piston return spring

Insufficient push rod to master cylinder clearance Adjust

Worn brake lining Replace

Grease or oil on lining surface Replace

Parking brake cable sticking Replace

Auto adjuster malfunction Correct

Excessive parking brake lever stroke Adjust the parking

brake lever stroke or
check the parking
brake cable routing

58-6
SERVICE ADJUSTMENT PROCEDURE
BRAKE PEDAL INSPECTION AND ADJUSTMENT
1. Pedal height

Pedal height (from top of pedal to toeboard) A . . . . . . . . . .

163-168 mm (6.417-6.614 in.)

If the pedal height is out of specification, adjust by the

following procedure.
1) Back off the stop lamp switch to a position where it does
not contact the pedal arm.
2) Turn the stop lamp switch until the clearance between
the stop lamp switch outer case and the pedal arm is
within the standard value, and tighten the lock nut.

Clearance between pedal and stop lamp switch B . . . . . . .

0.5 to 1.0 mm (0.02 to 0.039 in.)

2. Brake pedal free play.

Brake pedal free play C. . . . . . . . . . . . . . . . . . . . . . .

10-15 mm (0.394-0.591 in.)

3. Start the engine, apply the brake pedal with approximately

50 kg (110 lbs.) of force, and measure the clearance between
the brake pedal and the floor board.

Pedal to floor board clearance D

when pedal is depressed 50 kg (110 lbs.) force . . . . . . .
70 mm (2.76 in.) or more
when pedal is fully depressed without brake fluid . . . . .
50 mm (1.97 in.) or more

58-7
BRAKE BOOSTER OPERATION TEST WITHOUT
A TESTER
For a simple check of the brake booster operation, make the
following tests.
1. Run the engine for one or two minutes, then stop it. Depress
the brake pedal several times using normal foot pressure. If
the pedal goes down further the first time, but gradually rises
after the second or third time, the brake booster is
functioning properly. Go to step 2.
2. With the engine stopped, depress the brake pedal several
times.
Depress the brake pedal and start the engine.
If the pedal goes down slightly, the booster is in good
condition. Go to step 3.
3. With the engine running, depress the brake pedal and then
stop the engine.
Hold the pedal depressed for 30 seconds. If the pedal height
does not change, the booster is in good condition.

If one of the above three tests is not okay, check the vacuum
hoses, the check valve and the brake booster. Make any
necessary corrections. If all the tests are OK, unit is good.

BLEEDING OF BRAKE SYSTEM

1. Remove the reservoir cap and fill the brake fluid reservoir.

CAUTION
Do not allow brake fluid to remain on a painted surface.
Wash it off immediately.

NOTE
When pressure bleeding the system, do not depress the
brake pedal.

2. Connect a vinyl tube to the wheel cylinder bleeder screw and

insert the other end of tube in a half full container of brake
fluid.
3. Slowly pump the brake pedal several times.
4. While depressing the brake pedal fully, loosen the bleeder
screw until fluid starts to run out. Then close the bleeder
screw.

58-8
 GENERAL

5. Repeat steps 3 and 4 until there are no more bubbles in the

fluid.
6. Tighten the bleeder plug screw.

Bleeder screw tightening torque . . . . . . . . . . . . . . . . . . . . . . . .

7-9 Nm (70-90 kg.cm, 5.1-6.5 lb.ft)

7. Repeat the above procedure for each wheel in the sequence

shown in the illustration.

PARKING BRAKE STROKE ADJUSTMENT

1. Pull the brake lever with a force of approximately 20 kg (44
lbs.), and count the number of clicks.

Parking brake lever stroke [Standard value]. . . . . . . . . . . . . .

6-7 clicks

2. If the number of notches is not within the standard value,

adjust the cable length with the adjusting nut of the
equalizer.

3. The indicator light will go out when the brake lever is fully
released, and will light with the lever is pulled up one notch.
If it does not operate, check the bulb and/or switch.
4. After the adjustment, check that the rear brakes do not drag
with the parking brake lever released.

58-9
 BRAKE PEDAL

BRAKE PEDAL

COMPONENTS
[Hydraulic type clutch]

58-10
 BRAKE PEDAL

REMOVAL
1. Remove the lower crash pad assembly.
2. Remove the steering column shaft mounting bolts (Refer to
Steering Group).
3. Remove the clutch pedal assembly.
4. Remove the console assembly (Refer to Body Group)
5. Remove the glove box housing cover and RH side lower
crash pad.
6. Remove the blower switch and air duct control assembly.
7. Drain the coolant, disconnect the heater hose and remove
the heater unit assembly (Refer to Air Conditioning Group).
8. Remove the stop lamp switch connector.
9. Remove the return spring.
10. Disconnect the operating rod and brake pedal from each
other.

11. Remove the stopper and the washer.

12. Loosen the booster mounting nut and remove the right side
pedal support member.
13. Remove the pedal support (left) and remove the pedal from
the left.

58-11
 BRAKE PEDAL

INSPECTION
1. Check the bushing for wear.
2. Check the brake pedal for distortion.
3. Check the brake pedal return spring for damage.
4. Check the stop lamp switch.
1) With an ohmmeter connected to the stop lamp switch
terminals, check for continuity.
2) If there is no continuity when the plunger is depressed
and there is continuity when the plunger is released, the
stop lamp switch is normal.

INSTALLATION
1. Apply chassis grease to the bushing bore and flanges.

NOTE
Install the bushing in the correct position as shown in the
illustration.

2. Apply chassis grease to the sliding surface of the brake pedal

and operating rod clevis pin.

CAUTION
Be sure to install the split pin on the operating rod clevis
pin.

3. Adjust the brake pedal height and free play.

4. Adjust the clutch pedal stroke and free play.
5. Install the steering shaft.

58-12
MASTER CYLINDER

COMPONENTS

TORQUE : Nm (kg.cm, lb.ft)

REMOVAL
1. Remove the fluid level warning device connector.
2. Disconnect the brake lines from the master cylinder, and
plug the open ports.

CAUTION
Do not allow brake fluid to remain on a painted surface.
Wash it off immediately.

3. Remove the master cylinder mounting nuts. Disconnect the

proportioning valve mounting bracket, then lift out the
master cylinder.

DISASSEMBLY
1. Remove the reservoir cap and drain the brake fluid into a
suitable container.
2. Remove the reservoir from the master cylinder.

NOTE
If necessary, support the master cylinder in a vise at its
flange not at its bore.

3. While depressing the piston, remove the snap ring.

58-13
 MASTER CYLINDER

4. Remove the primary and secondary pistons from the master

cylinder body.

NOTE
1) Be careful not to damage the cylinder bore.
2) Do not disassemble the primary and secondary piston
assemblies.

INSPECTION
1. Check the inner surface of the master cylinder body for rust
or scoring.
2. Check the primary and secondary pistons for rust, scoring,
wear, damage or deterioration.
3. Check the primary and secondary piston springs for
deterioration.

ASSEMBLY
1. Apply the specified brake fluid to the inner surface of the
master cylinder body and to the outside of the secondary and
primary pistons.

Recommended brake fluid . . . . . . . . . . DOT 3 or equivalent

2. Carefully insert the spring and secondary piston assembly in

the master cylinder bore.
3. Carefully insert the primary piston assembly in the master
cylinder bore.
4. Depress the primary piston and install the retaining ring in
the cylinder bore groove as illustrated.

58-14
 MASTER CYLINDER

5. Install the reservoir cap on the master cylinder.

6. Lubricate the two grommets at both inside and outside with
genuine brake fluid and then insert them into the master
cylinder body.

NOTE
Whenever the reservoir is replaced, the grommets must
also be replaced.

7. Press the reservoir into the grommets with the fluid level
indicator socket facing inboard. The reservoir should snap in
place indicating that it is secure as illustrated.
8. Connect the fluid level warning connector in the socket on
the reservoir.

INSTALLATION
1. Install the master cylinder on the brake booster with two
nuts.

Nut . . . . . . . . . . . . . . . 8-12 Nm (80-120 kg.cm, 6-9 lb.ft)

2. Connect two brake tubes and fluid level warning connector.

Brake tube flare nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13-17 Nm (130-170 kg.cm, 9-12 lb.ft)

3. Fill the master cylinder reservoir with brake fluid and bleed
the system.

58-15
 BRAKE BOOSTER

BRAKE BOOSTER

COMPONENTS

TORQUE : Nm (kg.cm, Ib.ft)

CHECK VALVE OPERATION TEST

REMOVAL
1. Remove the master cylinder.
(Refer to page 58-13)

CAUTION
Do not allow brake fluid to remain on a painted surface.
Wash it off immediately

58-16
2. Disconnect the vacuum hose from the booster.
3. Remove the operating rod from the brake pedal.
4. Loosen the booster mounting nuts.
5. Lift out the booster assembly.

INSTALLATION
1. When the booster assembly is installed, replace the packing
at each end of the booster mounting holder, if necessary.
2. Install brake booster and tighten the mounting nuts.

Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-12 Nm (80-120 kg.cm, 6-9 Ib.ft)

3. Connect clevis to brake pedal with clevis pin and install the
split pin to the clevis pin.
4. Install master cylinder.
5. Connect vacuum hose to brake booster.
6. Pay attention to the direction of the check valve when
installing.
7. Fill brake reservoir with brake fluid and bleed the system.
8. Check for fluid leakage.
9. Check and adjust the brake pedal (Refer to page 58-7).
10. After installation, apply sufficient grease to the clevis and
brake pedal contacting points.

58-17
 BRAKE LINE

BRAKE LINE

COMPONENTS

TORQUE : Nm (kg.cm, lb.ft)

INSPECTION
1. Check the brake lines for cracks, crimps and corrosion.
2. Check the brake hoses for cracks, damage and leakage.
3. Check the brake line flare nuts for damage and leakage.

INSTALLATION
1. Install the brake hoses without twisting them.
2. The brake lines should be installed away from sharp edges,
weld beads or moving parts.
3. Tighten the connections to the specified torque.

Flare nuts . . . . . 13-17 Nm (130-170 kg.cm, 9-12 Ib.ft)

Brake hose to front caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25-30 Nm (250-300 kg.cm, 18-22 Ib.ft)

58-18
 PROPORTIONING VALVE

PROPORTIONING VALVE
Do not disassemble the proportioning valve. The proportioning
valve regulates the distribution of fluid pressure to the front and
rear brakes to prevent skidding in the event of rear wheel lock,
and to obtain greater braking efficiency.

PORPORTIONING VALVE FUNCTION TEST

1. Connect two pressure gauges, one the input side and one
to the output side of the proportioning valve.

NOTE
Be sure to bleed the system after you connect the pressure
gauges.

2. With the brakes applied, measure the input pressure and the
output pressure. If the measured pressures are within the
ranges as illustrated, the proportioning valve is good.
3. Reconnect the brake lines in their original positions and
bleed the system.

NOTE
This figure shows characteristics of the proportioning
valve during pressure increase.

PROPORTIONING VALVE INSTALLATION

1. Install the brake lines according to the illustration.
2. Tighten the flare nuts and bleed the system.

Tightening torque
Brake tube flare nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-17 Nm (130-170 kg.cm, 9-12 lb.ft)
Proportioning valve mounting nut . . . . . . . . . . . . . . . . . . . . .
8-12 Nm (80-120 kg.cm, 5.8-8.7 Ib.ft)

58-19
 FRONT DISC BRAKE

FRONT DISC BRAKE

REPLACEMENT OF BRAKE PADS

The brake pads have wear indicators that contact the brake disc
when the brake pad thickness becomes 2 mm (0.08 in.). The
wear indicators will generate a squealing sound to warn the
driver.

Removal

1. Remove the lower bolt and lift the caliper assembly up and
out of the way. Secure it with wire or some other retaining
method.
2. Remove the pads.

CAUTION
Do not depress the brake pedal while disassembling the
pads.

58-20
 FRONT DISC BRAKE

Inspection
1. Check the pads for wear or oil contamination and replace,
if necessary.

CAUTION
The pads for the right and left wheels should be replaced
at the same time. Never “split” or intermix brake pad sets.
All four pads must be replaced as a complete set.

Standard value Service limit

Pad thickness mm (in.)

9.0 (0.394) 1.0 (0.039)

2. Check the shims for damage or deformation.

Installation
1. Install the pad clips.
2. Install the pads onto each pad clip.

NOTE
Position the pad with its wear indicator toward the disc
side and facing upward.

3. Seat the piston in the cylinder using Special Tool

(09581-11000).

4. Install the new pads. The shims are attached to the each
pad as illustrated.

CAUTION
Never apply grease to the disc or pads.
 FRONT DISC BRAKE

5. Install the bolt and tighten to the specified value.

Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22-31 Nm (220-320 kg.cm, 16-23 lb.ft)

CALIPER ASSEMBLY
Removal
1. Remove the wheel and tire.
2. Disconnect the brake hose.
3. Remove the pads.
4. Remove the sleeve.
5. Remove the pin boot and sleeve boot.
6. Remove the caliper assembly.

Disassembly

1. Remove the piston boot.

2. Remove the piston using compressed air.
CAUTION
1) Do not place fingers in front of the piston when using
compressed air.
2) Be careful not to splatter the brake fluid.

3. Remove the piston seal from the caliper using a screw driver.

58-22
 FRONT DISC BRAKE

INSPECTION
1. Check the cylinder for wear, damage, cracks and rust.
2. Check the piston for rust, damage, cracks and wear on the
outer surface.
3. Check the sleeve and pin for damage and rust.
4. Check the pad spring and boots for damage.
5. Check the carrier for damage, rust, wear and cracks.
CAUTION
1) Do not use sand paper on the piston surface.
2) All rubber parts must be replaced with new ones.

6. Inspect the disc using calipers and dial gauge.

Standard value Service limit

Thickness of disc mm (in.) 19 (0.75) 17 (0.67)

Runout of disc mm (in.) 0.15 (0.006)

7. If necessary, replace the brake disc.

1) Remove the torque plate from the knuckle and suspend

it with a wire.
2) Using special tool (09526-11001), disconnect the
driveshaft from the hub, and remove the brake disc and
hub.
3) Install the brake disc and hub assembly to the axle shaft.
4) Install the axle nut and washer, then tighten the axle
nut.

Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
196-255 Nm (2000-2600 kg.cm, 145-188 Ib.ft)

5) Install the torque plate onto the knuckle.

ASSEMBLY
1. Clean all components with isopropyl alcohol except the pads
and shim.
2. Apply rubber grease to the piston seal and install the piston
seal in the cylinder.

58-23
 FRONT DISC BRAKE

3. Assemble the piston and piston boots according to the

following procedure.
1) Apply rubber grease to the caliper bore, outside surface
of the piston and piston boot.
2) Install the piston boot on the piston as illustrated.
3) Insert the piston boot in the inner groove of caliper and
slide the piston into the caliper.

4. Assemble the sliding parts according to the following

procedure.
1) Apply rubber grease to the outside surface of the sleeve
and pin, pin and sleeve bore of the caliper, pin boot and
sleeve boot.
2) Insert the boots into the groove of the caliper.

5. Install the pads.

NOTE
Do not apply grease to the disc or pads.

6. Tighten the brake hose connecting bolt.

Tightening torque Nm (kg.cm, Ib.ft)

Sliding pin 34-44 (350-450, 25-33)

Sliding bolt 22-31 (220-320, 16-23)
Carrier mounting bolt 64-74 (650-750, 47-54)
Brake hose mounting oil bolt 2 5 - 2 9 (250-300, 18-22)

NOTE
1) Check that the surfaces of the pin and bolts are not
damaged before tightening.
2) Bleed the system.
Depress the pedal several times and check for fluid
leakage from all connecting parts.

58-24
REAR DRUM BRAKE (BENDIX)

REMOVAL
1. After removing the wheel, remove the brake drum.
2. Remove the automatic adjuster spring and adjuster lever.

3. Spread the shoes and remove the adjuster strut.

4. Remove the shoe to shoe spring and shoe hold down spring.
5. Remove the parking cable at the parking lever.
6. Remove the clip on the parking brake cable at the backing
plate.
7. Remove the brake line from the wheel cylinder.
8. Remove the wheel cylinder assembly together with the
backing plate.

58-25
 REAR DRUM BRAKE (BENDIX)

INSPECTION
1. Inspect the backing plate for distortion and damage.
2. Inspect the wheel cylinder for excessive corrosion or
damage.
3. Inspect the brake lining and drum for proper contact.
4. Inspect the brake lining for wear or oil contamination.

5. Measure the brake drum inside diameter.

Check the runout of the brake drum using a dial indicator.
6. Measure the brake shoe lining thickness.
mm (in.)

Standard value Service limit

Drum inside diameter 180 (7.087) 182 (7.165)

Brake drum runout - 0.015 (0.0006)
Lining thickness 4.85 (0.191) 0.8 (0.039)

INSTALLATION
1. Apply a light coating of lubricant to the illustrated surfaces.

Recommended lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wolfracote grease per ES-2825 or equivalent

1) Six ledges of the backing plate.

2) Where shoe web (anchor end) contacts anchor plate.
3) Where automatic adjuster lever contacts adjuster socket
and automatic adjuster pin.
4) Where parking parke lever contacts shoe web (strut
area).

2. Attach the parking brake cable to the parking brake lever and
install the clip at the backing plate.
3. Install the brake shoes with the shoe hold down springs.
4. Connect the shoe to shoe spring.

58-26
5. Install the adjuster strut assembly between the leading shoe
slot and the slot in the trailing shoe and the parking brake
lever.
6. Install the adjuster lever in the groove located in the adjuster
pin and into the slot of the adjuster socket that fits into the
leading shoe web.

NOTE
The adjuster pivot nut blade is marked R or L for right hand
and left hand brake assemblies. The pivot nut must be
installed with the groove on the side of the blade facing
outward.

7. Attach the adjuster spring.

8. Install the backing plate and tighten the bolts.
9. Install the brake drum and wheel/tire assembly.

REPLACEMENT OF WHEEL CYLINDER

Wheel cylinders should not be disassembled unless they are
leaking. Carefully pull the lower edges of the wheel cylinder
boots away from the cylinder, and note whether or not the
interior is wet with brake fluid. Excessive fluid at this point
indicates leakage past the piston cups and a need for wheel
cylinder overhaul.

DISASSEMBLY AND INSPECTION

1. Remove the brake shoes as outlined before.
2. Remove the boots and pull out the pistons, cups, spring and
expander assembly.
3. Remove the bleeder screw from the cylinder.
4. Inspect the pistons for scoring or other visible damage.
Replace, if necessary.
5. Inspect the cylinder bore for scoring or rust.

58-27
 REAR DRUM BRAKE (BENDIX)

ASSEMBLY
1. Apply a light coat of brake fluid (DOT 3) to all internal parts.
2. Install the bleeder screw into the cylinder and tighten to
specifications.
3. Insert the return spring and cup expander assembly, cups
and pistons into their respective position in the cylinder bore.
Place a boot over each end of the cylinder.

NOTE
Ensure that the brake line is installed in the lower wheel
cylinder port and the bleed screw in the upper port.

4. Bleed the brake system.

58-28
REAR DRUM BRAKE (MANDO)

COMPONENTS

TORQUE : Nm (kg.cm, Ib.ft)

REMOVAL
1. Removing the wheel and tire, then remove brake drum.

NOTE
If the brake drum is difficult to remove, insert bolts into
the threaded holes of the drum then remove it.

2. After removing the nut, remove the rear hub with the brake
drum.

3. Remove the abut end shoe spring, shoe hold down spring.
4. Remove the shoes and adjuster as an assembly.

58-29
 REAR DRUM BRAKE (MANDO)

INSPECTION
1. Measure the brake drum inside diameter.
Check the runout of brake drum using a dial indicator.
mm (in.)

Standard value Service limit

Inside diameter 180 (7.1) 182 (7.165)

Out-of-rounded of brake - 0.015 (0.0006)
drum

2. Measure the brake shoe lining thickness.

Standard value Service limit

Lining thickness Leading-4.5 (0.177) 1.0 (0.039)

mm (in.) Trailing-4.6 (0.181)

3. Inspect the brake lining and drum for proper contact.

4. Inspect the wheel cylinder outside for excessive corrosion
and damage.
5. Inspect the backing plate for wear or damage.

INSTALLATION
1. Apply the specified grease to the locations indicated in the
illustration and to each component.

o Shoe and backing plate contact surfaces

o Shoe and anchor plate contact surfaces

Recommended grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Multipurpose grease SAE J310, NLGI No.2

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2. Install the shoe hold down pin.

3. Assemble the return spring with the push rod shortened.

4. After assembling the drum components, pull the parking
brake lever all the way up several times.

WHEEL CYLINDER REPLACEMENT

1. Remove the brake shoe.
2. Disconnect the brake tube.
3. Remove the wheel cylinder assembly.

4. Remove the duct boot.

5. Remove the piston and piston cup.
6. Drive out the return spring.

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7. Before assembling the wheel cylinder, inspect the following
points.

1) Check the cylinder and piston for wear, damage and rust.
2) Check the cylinder body for damage and cracks.
3) Check the contact surface of the piston and shoes for
wear.
4) Check the piston spring for looseness.
8. Assembly is the reverse of the removal procedure.

NOTE
1) Clean the cylinder and inner part with isopropyl alcohol
before assembly.
2) Apply enough brake fluid to piston cups and cylinder.
3) Be sure to use new piston cups and dust boots.

Caution
Be careful not to lose the steel ball in the bleeder.

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 PARKING BRAKE

PARKING BRAKE
COMPONENTS

REMOVAL
1. Remove the rear console.
2. Loosen the adjusting nut and detach the parking brake cable.
3. Detach the parking brake switch assembly.
4. Remove the parking brake lever assembly.

5. Remove the wheel and tire.

6. Remove the brake drum.
7. Remove the brake shoes as outlined before.
8. Detach the parking brake cable from the parking lever.

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 PARKING BRAKE

7. Remove the parking brake cable retaining ring in the rear

of the backing plate.

8. Remove the rear seat cushion assembly and roll up the

carpet.
9. Loosen the parking brake cable clamp and remove the
parking brake cable assembly.

INSPECTION
1. Check the parking brake switch operation.
2. Check the parking brake lever ratchet for wear.
3. Check the parking brake cable for fraying or damage.

INSTALLATION
1. Check the parking brake cables for left and right
identification marks and install accordingly.

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 PARKING BRAKE

2. Move the adjuster lever all the way back when installing the
shoe-to-shoe spring.

3. Install the grommets in the direction shown in the

illustration.

4. Apply a coating of the specified grease to the sliding parts

of the ratchet plate and ratchet pawl.

Specified grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Multipurpose grease SAE J310, NLGl No.2

5. After installing the cable adjuster, adjust the parking brake

lever stroke.

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