Service Brakes: Group 35A

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35A-1

GROUP 35A

SERVICE BRAKES
CONTENTS

GENERAL DESCRIPTION. . . . . . . . . 35A-2 BRAKE PEDAL. . . . . . . . . . . . . . . . . . 35A-22


REMOVAL AND INSTALLATION . . . . . . . . 35A-22
BASIC BRAKE SYSTEM DIAGNOSIS 35A-3 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 35A-23
INTRODUCTION TO BASIC BRAKE SYSTEM
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . 35A-3 MASTER CYLINDER ASSEMBLY AND
BASIC BRAKE SYSTEM DIAGNOSTIC BRAKE BOOSTER . . . . . . . . . . . . . . . 35A-24
TROUBLESHOOTING STRATEGY . . . . . . 35A-3
REMOVAL AND INSTALLATION . . . . . . . . 35A-24
SYMPTOM CHART. . . . . . . . . . . . . . . . . . . 35A-3
MASTER CYLINDER . . . . . . . . . . . . . . . . . 35A-26
SYMPTOM PROCEDURES . . . . . . . . . . . . 35A-3
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 35A-27

SPECIAL TOOLS. . . . . . . . . . . . . . . . 35A-12 FRONT DISC BRAKE ASSEMBLY . . 35A-27


REMOVAL AND INSTALLATION . . . . . . . . 35A-27
ON-VEHICLE SERVICE. . . . . . . . . . . 35A-12
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 35A-28
BRAKE PEDAL CHECK AND
DISASSEMBLY AND ASSEMBLY . . . . . . . 35A-29
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 35A-12
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 35A-30
BRAKE BOOSTER OPERATING TEST . . . 35A-14
CHECK VALVE OPERATION CHECK . . . . 35A-14
REAR DISC BRAKE ASSEMBLY . . . 35A-31
BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . 35A-15
REMOVAL AND INSTALLATION . . . . . . . . 35A-31
BRAKE FLUID LEVEL SENSOR CHECK. . 35A-16
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 35A-32
FRONT DISC BRAKE PAD CHECK AND
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 35A-16 DISASSEMBLY AND ASSEMBLY . . . . . . . 35A-33
DISC BRAKE ROTOR CHECK. . . . . . . . . . 35A-18 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 35A-34
BRAKE DISC THICKNESS CHECK . . . . . . 35A-19
BRAKE DISC RUN-OUT CHECK AND
SPECIFICATIONS . . . . . . . . . . . . . . . 35A-35
CORRECTION . . . . . . . . . . . . . . . . . . . . . . 35A-20 FASTENER TIGHTENING
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . 35A-35
MASTER CYLINDER FUNCTION CHECK. 35A-21
GENERAL SPECIFICATIONS . . . . . . . . . . 35A-36
SERVICE SPECIFICATIONS . . . . . . . . . . . 35A-36
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . 35A-37
SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . 35A-37
35A-2 SERVICE BRAKES
GENERAL DESCRIPTION

GENERAL DESCRIPTION
M1351000100365
Top components such as Bremboä brakes, EBD and Improved stability
sports ABS improve braking power and braking sta- 1. Sports ABS (4-wheel anti-lock braking system) is
bility. used to prevent slipping caused by the vehicle
CAUTION wheels locking up in order to maintain an appro-
Take care not to contact the parts or tools to the priate braking distance, and also to maintain a
caliper because the paint of caliper will be stable vehicle posture and steering performance.
scratched. 2. Adoption of an electronic brake-force distribution
(EBD) makes it possible to maintain the maxi-
FEATURES mum amount of braking force even when the
. vehicle's load is unevenly distributed.
Improved braking performance 3. Front- and rear-wheel X-type brake line layout is
1. A 8+9-inch tandem vacuum booster is utilized to used.
provide high braking force with a small pedal 4. Ventilated discs improve anti-fading performance.
depression force.
2. Bremboä 17-inch 4-pot front ventilated disc .

Improved serviceability
brakes and Bremboä 16-inch 2-pot rear venti-
1. A diagnosis function has been adopted for the
lated disc brakes are adopted to provide stable
ABS system in order to make inspection easier.
braking force and improved braking feel.
2. An outer disc method separated hub and rotor is
.

featured to make removal and installation easier.


3. The master cylinder reservoir tank cap is colored
white to make identification easier.
4. The ABS-ECU and hydraulic unit are integrated
to make them more compact and light weight.

CONSTRUCTION DIAGRAM

BRAKE BOOSTER
ASSEMBLY

BRAKE MODULATOR
HYDRAULIC UNIT
(INTEGRATED WITH
THE ABS-ECU)

10064AU

REAR DISC BRAKE


PARKING BRAKE
BRAKE MASTER LEVER ASSEMBLY
CYLINDER ASSEMBLY

FRONT DISC BRAKE


AC211387 AB

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SERVICE BRAKES
BASIC BRAKE SYSTEM DIAGNOSIS
35A-3
BASIC BRAKE SYSTEM DIAGNOSIS
INTRODUCTION TO BASIC BRAKE SYSTEM DIAGNOSIS
M1351009700267
Hydraulic brakes are composed of the brake pedal,
master cylinder, brake booster and disc brakes. Mal-
functions such as insufficient braking power or the
generation of noise may occur due to wear, damage
or incorrect adjustment of these components.
BASIC BRAKE SYSTEM DIAGNOSTIC TROUBLESHOOTING STRATEGY
M1351009800264
Use these steps to plan your diagnostic strategy. If 2. Verify that the condition described by the
you follow them carefully, you will be sure that you customer exists.
have exhausted most of the possible ways to find a 3. Find the malfunction by following the symptom
basic brake system fault. chart.
1. Gather information from the customer. 4. Verify malfunction is eliminated.
SYMPTOM CHART
M1351009900272

SYMPTOMS INSPECTION REFERENCE


PROCEDURE PAGE
Vehicle pulls to one side when brakes are applied 1 P.35A-3
Insufficient braking power 2 P.35A-4
Increased pedal stroke (Reduced pedal-to-floor board clearance) 3 P.35A-5
Brake drag 4 P.35A-6
Scraping or grinding noise when brake are applied 5 P.35A-7
Squealing, groaning or chattering noise when brake are applied 6 P.35A-8
Squealing noise when brakes are not applied 7 P.35A-9
Groaning, clicking or rattling noise when brakes are not applied 8 P.35A-11

SYMPTOM PROCEDURES

INSPECTION PROCEDURE 1: Vehicle Pulls to One Side when Brakes are Applied

DIAGNOSIS
.

STEP 1. Check for oil, water, etc., on the pad


contact surface of all brakes.
Q: Is oil, water, etc., on the pad contact surface?
YES : Replace the part and determine the source/
cause of foreign material. Then go to Step 5.
NO : Go to Step 2.

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35A-4 SERVICE BRAKES
BASIC BRAKE SYSTEM DIAGNOSIS

STEP 2. Check disc brake pistons for smooth STEP 3. Check brake disc(s) for run out.
operation. Refer to P.35A-20.
(1) With engine not running, depress the brake pedal Q: Is runout outside of specifications?
rapidly several times to deplete booster vacuum YES : Repair or replace the brake disc(s) as
reserves. necessary. Then go to Step 5.
(2) Test each disc brake assembly one at a time. NO : Go to Step 4.
a. Remove the lower caliper bolt, then remove
caliper from mount.
b. Have an assistant slowly depress the brake STEP 4. Check brake discs for correct thickness.
pedal. Confirm piston(s) extend slowly and Refer to P.35A-19.
smoothly with no jumpiness. Repeat for each Q: Is the thickness outside of specifications?
disc brake assembly. YES : Repair or replace the brake disc(s) as
Q: Do (does) the piston(s) move correctly? necessary. Then go to Step 5.
YES : Go to Step 3. NO : Carry out the brake line bleeding. Then go
NO : Disassemble and inspect the brake to Step 5.
assembly (Front: refer to P.35A-29, Rear:
refer to P.35A-33). Then go to Step 5. STEP 5. Retest the system.
Q: Is the symptom eliminated?
YES : The procedure is complete.
NO : Start over at Step 1. If a new symptom
appears, refer to the appropriate symptom
chart.

INSPECTION PROCEDURE 2: Insufficient Braking Power


.

DIAGNOSIS STEP 3. Check the brake booster function.


Refer to P.35A-14.
STEP 1. Check that the specified brake fluid is Q: Is there fault?
used, its level is correct, and no contamination is YES : Replace the brake booster. Then go to Step
found. 6.
NO : Go to Step 4.
Q: Is there fault?
YES : Refill or replace with the specified brake
fluid DOT 3 or DOT 4. Bleed the brakes if STEP 4. Check for pinched or restricted brake
necessary (Refer to P.35A-15). Then go to tube or hose.
Step 6. Q: Is there a pinched or restricted brake tube or hose?
NO : Go to Step 2. YES : Replace that complete section of brake tube
or brake hose. Then go to Step 6.
STEP 2. Check for spongy (not firm brakes). NO : Go to Step 5.
(1) With engine not running, depress the brake pedal
rapidly several times to deplete booster vacuum STEP 5. Check for oil, water, etc., on the pad
reserve. contact surfaces of all brakes.
(2) With the brake pedal fully released, depress the
brake pedal slowly until it stops. Q: Is oil, water, etc., on the pad contact surface?
(3) With a measuring stick (ruler, etc.) next to the YES : Replace the part and determine the source/
brake pedal, depress the pedal firmly and cause of foreign material. Recheck
measure the distance the pedal traveled. symptom. Then go to Step 6.
NO : The procedure is complete.
Q: Is the distance greater than 20 mm (0.8 inch)?
YES : Bleed the brakes to remove air in the fluid
(Refer to P.35A-15). Then go to Step 6.
NO : Go to Step 3.

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SERVICE BRAKES
BASIC BRAKE SYSTEM DIAGNOSIS
35A-5
STEP 6. Recheck symptom.
Q: Is the symptom eliminated?
YES : The procedure is complete.
NO : Start over at step 1. If a new symptom
surfaces, refer to the appropriate symptom
chart.

INSPECTION PROCEDURE 3: Increased Pedal Stroke (Reduced Pedal-to-Floor Board Clearance)


.

DIAGNOSIS STEP 4. Check the master cylinder function.


Refer to P.35A-21.
STEP 1. Check for spongy (not firm brakes). Q: Is there fault?
(1) With engine not running, depress the brake pedal YES : Repair it. Then go to Step 7.
rapidly several times to deplete booster vacuum NO : Go to Step 5.
reserve.
(2) With the brake pedal fully released, depress the STEP 5. Check for brake fluid leaks.
brake pedal slowly until it stops.
(3) With a measuring stick (ruler, etc.) next to the Q: Is there leaks?
brake pedal, depress the pedal firmly and YES : Check the connection for looseness,
measure the distance the pedal traveled. corrosion, etc. Clean and repair as
necessary. If leaking in any tube or hose
Q: Is the distance greater than 20 mm (0.8 inch)? section, replace the complete tube or hose.
YES : Bleed the brakes to remove air in the fluid Then go to Step 7 .
(Refer to P.35A-15). Then go to Step 7. NO : Go to Step 6.
NO : Go to Step 2.

STEP 6. Check the clearance (too much) between


STEP 2. Check the pad for wear. the push rod and primary piston.
Refer to P.35A-16. Refer to P.35A-24.
Q: Is the pad thickness outside of specifications? Q: Is the clearance outside of specifications?
YES : Replace the part. Then go to Step 7. YES : Adjust the clearance. Then go to Step 7.
NO : Go to Step 3. NO : Go to Step 7.

STEP 3. Check the vacuum hose and check valve STEP 7. Recheck symptom.
for damage.
Refer to P.35A-14. Q: Is the symptom eliminated?
YES : The procedure is complete.
Q: Is there damage? NO : Start over at step 1. If a new symptom
YES : Replace the part. Then go to Step 7. surfaces, refer to the symptom chart.
NO : Go to Step 4.

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35A-6 SERVICE BRAKES
BASIC BRAKE SYSTEM DIAGNOSIS

INSPECTION PROCEDURE 4: Brake Drag


.

DIAGNOSIS

STEP 1. Check the parking brake operating lever return.


Q: Is there fault?
PARKING BRAKE
OPERATING LEVER
YES : Repair it. Then go to Step 9.
NO : Go to Step 2.

AC210519 AB

STEP 2. Check the brake shoe springs for breakage.


Q: Are the brake shoe springs broken?
SHOE
YES : Replace the spring. Then go to Step 9.
SPRINGS NO : Go to Step 3.

AC210519AC

STEP 3. Check the amount of grease at each sliding


section.
Refer to GROUP 36, Parking Brake Lining and Drum P.36-8.
Q: Is the grease amount low?
YES : Apply grease. Then go to Step 9.
NO : Go to Step 4.

STEP 4. Check the parking brake pull amount.


Refer to GROUP 36, On-vehicle Service − Parking Brake Lever
Stroke Check and Adjustment P.36-4.
Q: Is there fault?
YES : Adjust it. Then go to Step 9.
NO : Go to Step 5.

STEP 5. Check the clearance (too low) between the push


rod and primary piston.
Refer to P.35A-24.
Q: Is there fault?
YES : Adjust the clearance. Then go to Step 9.
NO : Go to Step 6.

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SERVICE BRAKES
BASIC BRAKE SYSTEM DIAGNOSIS
35A-7

STEP 6. Check the master cylinder piston return spring for


damage and return port for clogging.
Refer to P.35A-26.
Q: Is there damage?
YES : Replace the part. Then go to Step 9.
NO : Go to Step 7.

STEP 7. Check port for clogging.


Q: Is the port clogged?
YES : Repair it. Then go to Step 9.
NO : Go to Step 8.

STEP 8. Check disc brake pistons for sticking.


Depress the brake pedal, then release. Confirm each wheel
spins freely.
Q: Are all wheels stuck?
YES : Inspect that brake assembly. Then go to Step 9.
NO : Go to Step 9.

STEP 9. Recheck symptom.


Q: Is the symptom eliminated?
YES : The procedure is complete.
NO : Start over at step 1. If a new symptom surfaces, refer
to the symptom chart.

INSPECTION PROCEDURE 5: Scraping or Grinding Noise when Brakes are Applied


.

DIAGNOSIS

STEP 1. Check the front brakes, then rear brakes, for


metal-to-metal condition.
Q: Is the metal-to-metal contact evident?
YES : Repair or replace the components. Then go to Step 6.
NO : Go to Step 2.

STEP 2. Check for interference between the caliper and


wheel.
Q: Is there interference?
YES : Repair or replace the part. Then go to Step 6.
NO : Go to Step 3.

STEP 3. Check for interference between the dust cover and


brake disc.
Q: Is there interference?
YES : Repair or replace the part. Then go to Step 6.
NO : Go to Step 4.

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35A-8 SERVICE BRAKES
BASIC BRAKE SYSTEM DIAGNOSIS

STEP 4. Check the brake discs for cracks.


Q: Are there cracks?
YES : Repair or replace the part. Then go to Step 6.
NO : Go to Step 5.

STEP 5. Check for bent backing plate(s).


<REAR> Q: Is (Are) the backing plate(s) bent?
BACKING PLATE YES : Repair or replace the part. Then go to Step 6.
NO : Go to Step 6.

AC210519 AD

STEP 6. Recheck symptom.


Q: Is the symptom eliminated?
YES : The procedure is complete.
NO : Start over at step 1. If a new symptom surfaces, refer
to the symptom chart.

INSPECTION PROCEDURE6: Squealing, Groaning or Chattering Noise when Brakes are Applied
.

DIAGNOSIS STEP 3. Adjust the brake pedal or brake booster


pushrod.
STEP 1. Check the brake disc and pads for wear Refer to P.35A-12 or P.35A-24.
or cutting. Q: Are the brake pedal and the brake booster pushrod
adjusted correctly?
Q: Is there wear or cutting?
YES : Go to Step 4.
YES : Repair or replace the part. Then go to Step
NO : Adjust the brake pedal or the brake booster
4.
pushrod. Then go to Step 4.
NO : Go to Step 2.

STEP 4. Recheck symptom.


STEP 2. Check the calipers for rust.
Q: Is the symptom eliminated?
Q: Is there rust?
YES : The procedure is complete.
YES : Remove the rust. Then go to Step 4.
NO : Start over at step 1. If a new symptom
NO : Go to Step 3.
surfaces, refer to the symptom chart.

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SERVICE BRAKES
BASIC BRAKE SYSTEM DIAGNOSIS
35A-9

INSPECTION PROCEDURE 7: Squealing Noise when Brakes are not Applied

DIAGNOSIS
.

STEP 1. Check whether the backing plate is bent or loose


and interfering with the drum.
Q: Is there fault?
YES : Replace the part. Then go to Step 10.
NO : Go to Step 2.

STEP 2. Check whether the drum is damaged due to


interference with the backing plate or shoe.
Q: Is there damage?
YES : Replace the part. Then go to Step 10.
NO : Go to Step 3.

STEP 3. Check the brake drum for wear and the shoe
spring for damage.
Q: Is there wear or damage?
YES : Replace the part. Then go to Step 10.
NO : Go to Step 4.

STEP 4. Check the brake discs for rust.


Q: Are the brake discs rusted?
YES : Remove the rust by using sand paper. If still rusted,
turn the rotors with an on-the-car brake lathe. Then go
to Step 10.
NO : Go to Step 5.

STEP 5. Check the brake pads for correct installation.


Q: Are the pads installed incorrectly?
YES : Repair the pads. Then go to Step 10.
NO : Go to Step 6.

STEP 6. Check the calipers for correct installation.


Q: Are the calipers installed incorrectly?
YES : Repair the calipers. Then go to Step 10.
NO : Go to Step 7.

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35A-10 SERVICE BRAKES
BASIC BRAKE SYSTEM DIAGNOSIS

STEP 7. Check the wheel bearings for end play.


(1) Remove the brake discs.
<FRONT> (2) Place a dial gauge as shown, and measure the end play
while moving the hub in the axial direction.
Limit: 0.05 mm (0.002 inch)
Q: Does the measured end play exceed the limit?
YES : Replace the faulty hub assembly. Then go to Step 10.
NO : Go to Step 8.

AC102438 AC

<REAR>

AC205869AC

STEP 8. Check whether the brake booster or master


cylinder return is insufficient.
Q: Is the brake booster or master cylinder return
insufficient?
YES : Replace the part. Then go to Step 10.
NO : Go to Step 9.

STEP 9. Adjust the brake pedal or brake booster pushrod.


Refer to P.35A-12 or P.35A-24.
Q: Are the brake pedal and the brake booster pushrod
adjusted correctly?
YES : Go to Step 10.
NO : Adjust the brake pedal or the brake booster pushrod.
Then go to Step 10.

STEP 10. Recheck symptom.


Q: Is the symptom eliminated?
YES : The procedure is complete.
NO : Start over at step 1. If a new symptom surfaces, refer
to the symptom chart.

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SERVICE BRAKES
BASIC BRAKE SYSTEM DIAGNOSIS
35A-11

INSPECTION PROCEDURE 8: Groaning, Clicking or Rattling Noise when Brakes are not Applied.

DIAGNOSIS
.

STEP 1. Check whether foreign material has entered the


wheel covers.
Q: Is there foreign material?
YES : Remove it. Then go to Step 5.
NO : Go to Step 2.

STEP 2. Check for looseness of the wheel nuts.


Q: Are the wheel nuts loose?
YES : Tighten to 98 ± 10 N⋅m (73 ± 7 ft-lb). Then go to Step
5.
NO : Go to Step 3.

STEP 3. Check for looseness of the caliper installation


bolt.
Q: Is the caliper installation bolt loose?
YES : Tighten to 108 ± 10 N⋅m (80 ± 7 ft-lb) for the front
caliper. Tighten to 54 ± 5 N⋅m (40 ± 4 ft-lb) for the rear
caliper. Then go to Step 5.
NO : Go to Step 4.

STEP 4. Check the wheel bearings for end play.


(1) Remove the brake discs.
<FRONT> (2) Place a dial gauge as shown, and measure the end play
while moving the hub in the axial direction.
Limit: 0.05 mm (0.002 inch)
Q: Does the measured end play exceed the limit?
YES : Replace the faulty hub assembly. Then go to Step 5.
NO : Go to Step 5.

AC102438 AC

<REAR>

AC205869AC

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35A-12 SERVICE BRAKES
SPECIAL TOOLS

STEP 5. Recheck symptom.


Q: Is the symptom eliminated?
YES : The procedure is complete.
NO : Start over at step 1. If a new symptom surfaces, refer
to the symptom chart.

SPECIAL TOOLS
M1351000600285

TOOL TOOL NUMBER AND SUPERSESSION APPLICATION


NAME
MB991568 General service Adjustment of the brake booster
Push rod adjusting socket tool push rod protrusion amount

MB990964 MB990619-01 or • Pushing-in of the disc brake


A Brake tool set general service piston
B
A: MB990520 tool • Installation of the drum brake
Disc brake piston expander wheel cylinder piston cup
MB990964 B: MB990619
Installer
MB990998 MB990998-01 Provisional holding of the wheel
Front hub remover and bearing
installer

MB990998

ON-VEHICLE SERVICE
BRAKE PEDAL CHECK AND ADJUSTMENT
M1351000900350

BRAKE PEDAL HEIGHT


1. Turn up the carpet, etc. under the brake pedal.
2. Measure the brake pedal height as illustrated.
Standard value (A): 169.1 − 172.1 mm (6.7 − 6.8 inches)
[From the surface of melting sheet (floorboard) to the
face of pedal pad]
3. If the brake pedal height is not within the standard value,
follow the procedure below.
(1) Disconnect the stoplight switch connector.
(2) Loosen the stoplight switch by turning it approximately. 1/
A
AC006215AB
4 turns anticlockwise.
(3) Remove the brake booster. (Refer to P.35A-24.)
NOTE: With the master cylinder and brake pipe con-
nected, remove the brake booster only.

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SERVICE BRAKES
ON-VEHICLE SERVICE
35A-13
(4) Adjust the brake pedal height by turning the clevis.
NOTE: When the clevis is turned 180 degrees, the pedal
height is changed approximately 2.4 mm (0.09 in).
(5) Install the brake booster. (Refer to P.35A-24.)
CLEVIS
(6) Measure the brake pedal height, and ensure that the
measured value is within the specified value. When it is
out of the specified value, repeat Step (3) - (6).

AC006217AB

(7) Insert the stoplight switch until it's thread part touches the
stopper. Then lock the stoplight switch by turning it
STOPPER
approximately. 1/4 turns clockwise, and confirm that the
clearance between the switch plunger and the stopper is
as shown.
CAUTION
Check that the stoplight does not illuminate when the
0.5 - 1.0 mm
(0.02 - 0.04 in)
brake pedal is not depressed.
(8) Connect the connector at the stoplight switch.
AC101091AB
4. Return the carpet, etc.

BRAKE PEDAL FREE PLAY


1. With the engine stopped, depress the brake pedal two or
three times, After eliminating the vacuum in the power brake
booster, press the pedal down by hand, and confirm that the
amount of movement before resistance is met (the free play)
is within the standard value.
Standard value (B): 3 − 8 mm (0.12 − 0.31 inch)
2. If the brake pedal play is not within the standard value,
check the following, and adjust or replace if necessary:
B • Excessive play between the brake pedal and the clevis pin,
AC006219AB
or between the clevis pin and the brake booster operating
rod
• Brake pedal height
• Installation position of the stoplight switch, etc.

CLEARANCE BETWEEN BRAKE PEDAL AND


FLOORBOARD
1. Turn up the carpet, etc. under the brake pedal.
2. Start the engine, depress the brake pedal with
approximately 500 N (112 pounds) of force, and measure
the clearance between the brake pedal and the floorboard.
Standard value (C): 90 mm (3.5 inches) or more [From
the surface of melting sheet (floorboard) to the face of
pedal pad]
3. If the clearance is outside the standard value, check for air
trapped in the brake line and thickness of the disc brake
C pad. And then bleed the air and replace he disc brake pad
AC006220AB
as required.
4. Return the carpet etc. to its original position.

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35A-14 SERVICE BRAKES
ON-VEHICLE SERVICE

BRAKE BOOSTER OPERATING TEST


M1351001000286
1. For simple checking of the brake booster operation, carry
out the following tests:
GOOD
(1) Run the engine for one or two minutes, and then stop it. If
NO GOOD
the pedal depresses fully the first time but gradually
becomes higher when depressed succeeding times, the
booster is operating properly. If the pedal height remains
unchanged, the booster is defective. Go to step 2.

AC000870 AB

(2) With the engine stopped, step on the brake pedal several
WHEN ENGINE WHEN ENGINE times. Then step on the brake pedal and start the engine.
IS STOPPED IS STARTED
If the pedal moves downward slightly, the booster is in
good condition. If there is no change, the booster is
defective. Go to step 3.

AC000871AB

(3) With the engine running, step on the brake pedal and
GOOD NO GOOD 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 the pedal rises, the booster is
defective.

AC000872 AB

2. If the above three tests are okay, the booster is OK. If one of
the above three tests is not okay, the check valve, vacuum
hose, or booster is defective. Check the check valve (Refer
to P.35A-14.), vacuum hose for leaks, high volume engine
vacuum applied to booster. Repair or replace as necessary.
If these are OK, replace booster and repeat this test starting
at Step 1.

CHECK VALVE OPERATION CHECK


M1351009000280

CAUTION
The check valve should not be removed from the vacuum
hose.
1. Remove the vacuum hose. (Refer to P.35A-24.)

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SERVICE BRAKES
ON-VEHICLE SERVICE
35A-15
CAUTION
If the check valve is defective, replace it as an assembly
unit together with the vacuum hose.
2. Check the operation of the check valve by using a vacuum
VALVE SPRING
pump.
A B
INTAKE VACUUM PUMP CRITERIA
BOOST- MANIFOLD CONNECTION
ER SIDE SIDE
(HOLDS)
(DOES NOT Connection at the brake A negative pressure
HOLD)
booster side (A) (vacuum) is created and
held.
Connection at the intake A negative pressure
AC000873AB manifold side (B) (vacuum) is not created.

BLEEDING
M1351001400369

CAUTION
Use only brake fluid DOT 3 or DOT 4. Never mix the speci-
fied brake fluid with other fluid as it will influence the brak-
ing performance significantly.
.

MASTER CYLINDER BLEEDING


The master cylinder used has no check valve, so if bleeding is
carried out by the following procedure, bleeding of air from the
brake pipeline will become easier. (When brake fluid is not con-
tained in the master cylinder.)
1. Fill the reserve tank with brake fluid.
2. Keep the brake pedal depressed.
3. Have another person cover the master cylinder outlet with a
finger.
4. With the outlet still closed, release the brake pedal.
5. Repeat steps 2 − 4 three or four times to fill the inside of the
master cylinder with brake fluid.
.

DISC BRAKE BLEEDING


CAUTION
AC000876
Take care not to contact the parts or tools to the caliper
because the paint of caliper will be scratched. And if there
is brake fluid on the caliper, wipe out quickly.
Connect a vinyl tube to the outer end of the air bleeder screw to
Air bleeder screw bleed the circuit of air. Then, connect the vinyl tube to the inner
end and bleed the circuit of air. Except for these, the conven-
tional procedures shall be followed. After the circuit has been
bled of air, tighten both air bleeder screws securely.
.

AC211983 AB

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;
35A-16

2
1

3
AC211984 AB
SERVICE BRAKES
ON-VEHICLE SERVICE

BRAKE LINE BLEEDING


CAUTION
Be sure to filter/strain the brake fluid being added to the
master cylinder reservoir tank. Debris may damage the
hydraulic unit.
Start the engine and bleed the air in the sequence shown in the
figure.

BRAKE FLUID LEVEL SENSOR CHECK


M1351009100317
The brake fluid level sensor is in good condition if there is no
continuity when the float surface is above "MIN" and if there is
continuity when the float surface is below "MIN".

AC006224AB

FRONT DISC BRAKE PAD CHECK AND


REPLACEMENT
M1351002300309

Required Special Tools:


• MB990520: Piston Expander
NOTE: The brake pads have indicators that contact the brake
WHEN NEW WHEN WORN
disc when the brake pad thickness becomes 2 mm (0.08 inch),
and emit a squealing sound to warn the driver.
PAD

BRAKE
DISC
WEAR INDICATOR

AC000879 AB

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SERVICE BRAKES
ON-VEHICLE SERVICE
35A-17
CAUTION
• Take care not to contact the parts or tools to the caliper
because the paint of caliper will be scratched. And if
there is brake fluid on the caliper, wipe out quickly.
• Whenever a pad must be replaced, replace both LH and
RH wheel pads as a set to prevent the vehicle from pull-
ing to one side when braking.
• If there is a significant difference in the thicknesses of
the pads on the left and right sides, check moving
parts.
1. Check the brake pad thickness through the caliper body
FRONT REAR
check port.

;
Standard value:
Pads <Front> 10.0 mm (0.39 inch)
<Rear> 9.0 mm (0.35 inch)
Minimum limit: 2.0 mm (0.08 inch)

Pads
AC211985 AB

2. When the thickness is less than the limit, always replace the
pads at an axle set.
(1) Holding the cross spring with one hand, pull the pin out of
the caliper.

AC211986

(2) Remove the pad from the caliper.


(3) To measure brake drag force after new pads have been
installed, use a spring scale to measure the turning
sliding resistance of the hub with the pads removed.

AC211987

(4) Clean the piston and, using special tool MB990520, push
the piston into the cylinder.
MB990520

AC211988 AB

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35A-18 SERVICE BRAKES
ON-VEHICLE SERVICE

REAR (5) Apply repair kit grease to the portions of the pads
FRONT
indicated on the left. At this time, make sure that the
grease will not be applied to any other surfaces.
(6) Mount the pads to the caliper so that its side with the
wear indicator is on the outside of the vehicle. With the
rear pads, ensure that the arrow on the pad faces in the
same direction as the brake disc turns when the vehicle
moves forward.

AC211989 AB

(7) Holding the cross spring with one hand, fit pins in the
Pins caliper.
Cross (8) Using a spring scale, measure the turning sliding
spring
resistance of the hub in the forward direction.
(9) Find the brake disc drag force [the difference in
measurements taken in step(3) and in step(8)].
Standard value: 69 N (15 pounds) or less
(10)If that drag force exceeds the standard value,
AC211990 AB disassemble the caliper assembly. Then check the piston
for contamination or rust, and confirm if the piston or the
piston seal is deteriorated.
DISC BRAKE ROTOR CHECK
M1351002900259

CAUTION
Disc brakes must be kept within the allowable
service values in order to maintain normal brake
operation.
Before turning the brake disc, the following condi-
tions should be checked.
INSPECTION ITEMS REMARKS
Scratches, rust, saturated lining materials and wear • If the vehicle is not driven for a long period of
time, sections of the discs that are not in contact
with the pads will become rusty, causing noise
and shuddering.
• If grooves and scratches resulting from excessive
disc wear are not removed prior to installing a new
pad assembly, there will be inadequate contact
between the disc and the lining (pad) until the
pads conform to the disc.
Run-out Excessive run-out of the discs will increase the pedal
depression resistance due to piston kick-back.
Change in thickness (parallelism) If the thickness of the disc changes, this will cause
pedal pulsation, shuddering and surging.
Inset or warping (flatness) Overheating and improper handling while servicing
will cause warping or distortion.

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SERVICE BRAKES
ON-VEHICLE SERVICE
35A-19
BRAKE DISC THICKNESS CHECK
M1351002400339
.

CAUTION
Take care not to contact the parts or tools to the caliper
because the paint of caliper will be scratched. And if there
is brake fluid on the caliper, wipe out quickly.
1. Using a micrometer, measure disc thickness at eight
positions, approximately 45 degrees apart and 10 mm (0.39
inch) in from the outer edge of the disc.
Standard value:
<Front> 32.0 mm (1.26 inch)
<Rear> 22.0 mm (0.87 inch)
Minimum limit:
<Front> 29.8 mm (1.17 inch)
<Rear> 20.4 mm (0.80 inch)
ACX00668AB
NOTE: Thickness variation (at least 8 positions) should not
be more than 0.015 mm (0.0006 inch).
2. If the disc thickness is less than the limits, replace it with a
new one.
CAUTION
• After a new brake disc is installed, always grind the
brake disc with on-the-car type brake lathe. If this step
is not carried out, the brake disc run-out exceeds the
specified value, resulting in judder.
• When the on-the-car type lathe is used, first install M12
flat washer on the stud bolt in the brake disc side
M12 FLAT WASHER according to the figure, and then install the adapter. If
the adapter is installed with M12 flat washer not seated,
the brake disc rotor may be deformed, resulting in inac-
curate grinding.
• Grind the brake disc with all wheel nuts diagonally and
equally tightened to the specified torque 100 N⋅m (74 ft-
lb). When all numbers of wheel nuts are not used, or the
tightening torque is excessive or not equal, the brake
disc rotor or drum may be deformed, resulting in jud-
der.
3. If thickness variation exceeds the specification, turn rotor
with an on-the-car type brake lathe ("Accuturn-8750" or
M12 FLAT WASHER equivalent).
If the calculated final thickness after turning the rotor is less
than the standard value, replace the disc.

AC006226 AB

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35A-20 SERVICE BRAKES
ON-VEHICLE SERVICE

BRAKE DISC RUN-OUT CHECK AND


CORRECTION
M1351009400437

CAUTION
Take care not to contact the parts or tools to the caliper
because the paint of caliper will be scratched. And if there
is brake fluid on the caliper, wipe out quickly.
1. Remove the brake assembly, and then hold it with wire.
2. Temporarily install the disc with the hub nut.
3. Place a dial gauge approximately 5 mm from the outer
circumference of the brake disc, and measure the run-out of
the disc.
Limit: 0.03 mm (0.0012 inch)

ACX00669AB

4. If the brake disc run-out exceeds the limit, correct it as


follows:
(1) Chalk phase marks on the wheel stud and the brake disc,
CHALK MARKS
which run-out is excessive as shown.

AC210711AB

<FRONT> (2) Remove the brake disc. Then place a dial gauge as
shown, and measure the end play by pushing and pulling
the wheel hub.
Limit: 0.05 mm (0.002 inch)
(3) If the end play exceeds the limit, disassemble the hub
and knuckle assembly to check each part.
(4) If the end play does not exceed the limit, dephase the
brake disc and secure it. Then recheck the brake disc
run-out.
AC102438 AC

<REAR>

AC205869AC

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SERVICE BRAKES
ON-VEHICLE SERVICE
35A-21
CAUTION
• After a new brake disc is installed, always grind the
brake disc with on-the-car type brake lathe. If this step
is not carried out, the brake disc run-out exceeds the
specified value, resulting in judder.
• When the on-the-car type lathe is used, first install M12
flat washer on the stud bolt in the brake disc side
M12 FLAT WASHER according to the figure, and then install the adapter. If
the adapter is installed with M12 flat washer not seated,
the brake disc rotor may be deformed, resulting in inac-
curate grinding.
• Grind the brake disc with all wheel nuts diagonally and
equally tightened to the specified torque 100 N⋅m (74 ft-
lb). When all numbers of wheel nuts are not used, or the
tightening torque is excessive or not equal, the brake
disc rotor or drum may be deformed, resulting in jud-
der.
5. If the run-out cannot be corrected by changing the phase of
the brake disc, replace the brake disc or grind it with the on-
M12 FLAT WASHER the-car type brake lathe ("Accuturn-8750" or equivalent).

AC006226 AB

MASTER CYLINDER FUNCTION CHECK


M1351010200200
1. Remove the reservoir cap and diaphragm.
2. While watching the open reservoir from a distance of 50 cm
(20 inches), have an assistant depress the brake pedal.
If there was a stream of brake fluid rising from the reservoir,
proceed to Step 3.
If there was no stream of brake fluid rising from the
reservoir, repair or replace the master cylinder.
3. While watching the open reservoir from a distance of 50 cm
(20 inches), have the assistant release the brake pedal.
If there was a small amount of air bubbles rising through the
brake fluid, master cylinder function is normal.
If there were no bubbles rising through the brake fluid, repair
or replace the master cylinder.

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35A-22 SERVICE BRAKES
BRAKE PEDAL

BRAKE PEDAL
REMOVAL AND INSTALLATION
M1351003400310

Post-installation Operation
• Brake Pedal Adjustment (Refer to P.35A-12.)

12 ± 2 N·m
8 107 ± 17 in-lb

3 1
2

5
7
14 ± 3 N·m
124 ± 26 in-lb 4
6

AC211554 AB

REMOVAL STEPS REMOVAL STEPS (Continued)


1. HARNESS CONNECTOR 5. BRAKE BOOSTER PIN
2. STOPLIGHT SWITCH 6. BRAKE PIN ASSEMBLY
3. BRAKE PEDAL CLIP 7. BRAKE PEDAL PAD
4. BRAKE PEDAL STOPPER >>A<< 8. BRAKE PEDAL ASSEMBLY

INSTALLATION SERVICE POINT


.

>>A<< BRAKE PEDAL ASSEMBLY INSTALLATION


Tighten the brake booster mounting nuts (A), and then the
brake pedal assembly mounting bolts (B).
B B NOTE: The brake pedal assembly can not be positioned cor-
rectly if the brake pedal assembly mounting bolts (B) are tight-
ened first as the their holes are oblong holes.
A A

AC006234 AB

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SERVICE BRAKES
BRAKE PEDAL
35A-23
INSPECTION
M1351003500146
.

STOPLIGHT SWITCH CHECK


1. Connect an ohmmeter between the stoplight switch
connector terminals.
2. There should be no continuity between the terminals when
the plunger is pushed in as shown. There should be
NO CONTINUITY CONTINUITY continuity when it is released.

4 mm (0.16 in)
AC006235AB

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35A-24 SERVICE BRAKES
MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER

MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER


REMOVAL AND INSTALLATION
M1351003700311

Pre-removal Operation Post-installation Operation


• Brake Fluid Draining • Brake Pedal Adjustment (Refer to P.35A-12.)
• Air Intake Hose and Air Cleaner Removal (Refer to • Air Intake Hose and Air Cleaner Installation (Refer to
GROUP 15, Air Cleaner P.15-7.) GROUP 15, Air Cleaner P.15-7.)
• Strut Tower Bar Removal (Refer to GROUP 42, Strut • Strut Tower Bar Removal (Refer to GROUP 42, Strut
Tower Bar P.42-12.) Tower Bar P.42-12.)
• Brake Fluid Supplying and Air Bleeding (Refer to P.35A-
15.)

4
2
3
11
15 ± 2 N·m
12 ± 1 ft-lb
12
8
5 1 10

6 9
10 ± 2 N·m 22 ± 3 N·m 14 ± 3 N·m
89 ± 17 in-lb 16 ± 2 ft-lb 124 ± 26 in-lb
5
15 ± 2 N·m
12 ± 1 ft-lb

7
14
16 ± 1 N·m
12 ± 1 ft-lb 13

SEALANT: 3MTM AAD PART


NO. 8661, 8663, 8672, 8678,
8679 OR EQUIVALENT
AC211993 AB

MASTER CYLINDER REMOVAL BRAKE BOOSTER REMOVAL


STEPS STEPS
1. CLUTCH HOSE CONNECTION 1. CLUTCH HOSE CONNECTION
2. BRAKE FLUID LEVEL INDICATOR 2. BRAKE FLUID LEVEL INDICATOR
SWITCH CONNECTOR SWITCH CONNECTOR
3. BRAKE FLUID RESERVOIR CAP 5. BRAKE TUBE CONNECTION
4. BRAKE FLUID LEVEL INDICATOR 6. BRAKE MASTER CYLINDER
SWITCH ASSEMBLY
5. BRAKE TUBE CONNECTION >>B<< • PUSH ROD PROTRUSION
6. BRAKE MASTER CYLINDER AMOUNT CHECK AND
ASSEMBLY ADJUSTMENT

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SERVICE BRAKES
MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER
35A-25
BRAKE BOOSTER REMOVAL
STEPS (Continued)
>>A<< 7. BRAKE BOOSTER VACUUM
HOSE (WITH BUILT-IN CHECK
VALVE)
8. BRAKE BOOSTER PIN
9. BRAKE BOOSTER PIN
ASSEMBLY
10. CLEVIS
• REMOVE A/C LIQUID PIPE B
FROM THE RETAINING CLIP.
(REFER TO GROUP 55A,
REFRIGERANT LINE.)
11. BRAKE BOOSTER ASSEMBLY
12. BRAKE BOOSTER BODY SEAL
FITTING REMOVAL STEPS
>>A<< 7. BRAKE BOOSTER VACUUM
HOSE (WITH BUILT-IN CHECK
VALVE)
13. BRAKE BOOSTER VACUUM
HOSE FITTING
Required Special Tools:
• MB991568: Push Rod Adjusting Socket

INSTALLATION SERVICE POINTS


.

>>A<< BRAKE BOOSTER VACUUM HOSE CONNECTION


Insert the brake booster vacuum hose to the brake booster
assembly with its paint mark facing upward, and then secure
the hose by using the hose clip.
.

>>B<< PUSH ROD PROTRUSION AMOUNT CHECK AND


ADJUSTMENT
1. Measure dimension (A).
Standard value (A): 8.98 − 9.23 mm (0.354 − 0.363 in)
NOTE: When a negative pressure of 66.7 kPa (19.7 inHg) is
applied to the brake booster, the push rod should protrude
10.27 - 10.53 mm (0.404 − 0.414 in).
A

MEASURING DISTANCE A

BLOCK GAUGE
AC006237AB

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35A-26 SERVICE BRAKES
MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER

2. If the protrusion amount is not within the standard value


range, adjust the push rod length by turning the push rod.
Use special tool MB991568 to turn the push rod while
holding the rod spline with angle-nose pliers.

ROD SPLINE

ANGLE-NOSE PLIERS

MB991568

AC006238AB

MASTER CYLINDER
M1351004200278

DISASSEMBLY AND ASSEMBLY


7
1

3 8
4
9
2

N 7 MASTER CYLINDER KIT

5 10
8 N
6
3 9 N

10 9 8
AC006239 AB BRAKE FLUID: DOT 3 OR DOT 4

DISASSEMBLY STEPS DISASSEMBLY STEPS (Continued)


1. BRAKE FLUID RESERVOIR CAP 5. BRAKE MASTER CYLINDER TO
2. BRAKE FLUID RESERVOIR FILTER RESERVOIR SEAL
3. BRAKE MASTER CYLINDER PIN 6. BRAKE MASTER CYLINDER PIN
4. BRAKE FLUID RESERVOIR 7. PISTON RETAINER

TSB Revision
SERVICE BRAKES
FRONT DISC BRAKE ASSEMBLY
35A-27
DISASSEMBLY STEPS (Continued)
8. PRIMARY PISTON ASSEMBLY
9. SECONDARY PISTON ASSEMBLY
10. MASTER CYLINDER BODY

INSPECTION
M1351004300208
• Check the inner surface of master cylinder body for rust or
pitting.
• Check the primary and secondary pistons for rust, scoring,
wear or damage.
• Check the diaphragm for cracks and wear.

FRONT DISC BRAKE ASSEMBLY


REMOVAL AND INSTALLATION
M1351006000322

CAUTION
Take care not to contact the parts or tools to the
caliper because the paint of caliper will be
scratched. And if there is brake fluid on the cali-
per, wipe out quickly.
Pre-removal Operation Post-installation Operation
• Brake Fluid Draining • Brake Fluid Supplying and Air Bleeding (Refer to P.35A-
15.)

108 ± 10 N·m
80 ± 7 ft-lb

30 ± 5 N·m
22 ± 4 ft-lb 1

N 2

AC211991 AB

REMOVAL STEPS REMOVAL STEPS (Continued)


1. BRAKE HOSE CONNECTION >>A<< 3. DISC BRAKE ASSEMBLY
2. GASKET 4. BRAKE DISC

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35A-28 SERVICE BRAKES
FRONT DISC BRAKE ASSEMBLY

INSTALLATION SERVICE POINT


.

>>A<< DISC BRAKE ASSEMBLY INSTALLATION


1. Find the drag force of the disc brake (Refer to P.35A-16).
Standard value: 69 (15 pound) or less
2. If that drag force exceeds the standard value, disassemble
the caliper assembly. Then check the piston for
contamination or rust, and confirm if the piston or the piston
seal is deteriorated.

INSPECTION
M1351006100222
BRAKE DISC CHECK
Disc wear (Refer to P.35A-19.)
Disc run-out (Refer to P.35A-20.)

TSB Revision
SERVICE BRAKES
FRONT DISC BRAKE ASSEMBLY
35A-29
DISASSEMBLY AND ASSEMBLY
M1351006200371

CAUTION
Take care not to contact the parts or tools to the
caliper because the paint of caliper will be
scratched. And if there is brake fluid on the cali-
per, wipe out quickly.

6
6 N 7 9N
8
10

4
3 14 ± 2 N·m
5 124 ± 18 in-lb
1

GREASE: REPAIR KIT GREASE


2
AC211994 AB

6
7 9
6 8

10 5 5
9
7
7
9
1

BRAKE CALIPER KIT SEAL AND BOOT REPAIR KIT SHIM SET

3 4
2
1
3
1
2
4

CLIP SET PAD SET

TSB Revision
35A-30 SERVICE BRAKES
FRONT DISC BRAKE ASSEMBLY

DISASSEMBLY STEPS DISASSEMBLY STEPS (Continued)


1. PIN 6. CALIPER BLEEDER
2. PAD ANTI-SQUEAK SPRING <<A>> 7. PISTON BOOT
3. PAD AND WEAR INDICATOR <<A>> 8. PISTON
ASSEMBLY <<B>> 9. PISTON SEAL
4. PAD ASSEMBLY 10. CALIPER BODY
5. SHIM

DISASSEMBLY SERVICE POINTS


CAUTION
Take care not to contact the parts or tools to the caliper
because the paint of caliper will be scratched. And if there
is brake fluid on the caliper, wipe out quickly.
When disassembling the disc brakes, disassemble both sides
(left and right) as a set.
.

<<A>> PISTON BOOT/PISTON REMOVAL


CAUTION
Do not remove one piston completely before trying to
remove the other piston, because it will become impossi-
ble to remove other pistons.
Remove the pistons by pumping in air slowly from the brake
WOOD BLOCK hose connection. Be sure to use a wood block and adjust the
height of the four pistons while so that the pistons protrude
evenly.

AC212148AB

<<B>> PISTON SEAL REMOVAL


CAUTION
Do not use a flat-tipped screwdriver or other tool to pre-
vent damage to inner cylinder.
1. Remove the piston seal with finger tip.
2. Clean the piston surface and inner cylinder with alcohol or
brake fluid DOT 3 or DOT 4.

INSPECTION
M1351006300293
• Check the cylinder for wear, damage or rust.
• Check the piston surface for wear, damage or rust.
• Check the caliper body for wear.
• Check the pad for damage or adhesion of grease, check the
backing metal for damage.
.

TSB Revision
SERVICE BRAKES
REAR DISC BRAKE ASSEMBLY
35A-31
PAD WEAR CHECK
WARNING
• Always replace both brake pads on each wheel as
a set (both front wheels or both rear wheels). Fail-
ure to do so will result in uneven braking, which
may cause unreliable brake operation.
• If there is significant difference in the thickness of
the pads on the left and right sides, check moving
parts.
Measure thickness at the thinnest and most worn area of the
pad.
Replace the pad assembly if pad thickness is less than the limit
value.
Standard value: 10.0 mm (0.39 inch)
Minimum limit: 2.0 mm (0.08 inch)

ACX00690

REAR DISC BRAKE ASSEMBLY


REMOVAL AND INSTALLATION
M1351007000217

CAUTION
Take care not to contact the parts or tools to the
caliper because the paint of caliper will be
scratched. And if there is brake fluid on the cali-
per, wipe out quickly.
Pre-removal Operation Post-installation Operation
• Brake Fluid Draining • Brake Fluid Filling and Air Bleeding (Refer to P.35A-15.)

± 5 N·m 1
± 4 ft-lb 15 ± 2 N·m
12 ± 1 ft-lb N 2

4
AC211992 AB

REMOVAL STEPS REMOVAL STEPS (Continued)


1. BRAKE HOSE CONNECTION >>A<< 3. DISC BRAKE ASSEMBLY
2. GASKET 4. BRAKE DISC

TSB Revision
35A-32 SERVICE BRAKES
REAR DISC BRAKE ASSEMBLY

INSTALLATION SERVICE POINT


.

>>A<< DISC BRAKE ASSEMBLY INSTALLATION


1. Find the drag force of the disc brake (Refer to P.35A-16).
Standard value: 69 N (15 pound) or less
2. If that drag force exceeds the standard value, disassemble
the caliper assembly. Then check the piston for
contamination or rust, and confirm if the piston or the piston
seal is deteriorated.

INSPECTION
M1351007100214
.

BRAKE DISC CHECK


Disc wear: Refer to P.35A-19.
Disc run-out: Refer to P.35A-20.

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SERVICE BRAKES
REAR DISC BRAKE ASSEMBLY
35A-33
DISASSEMBLY AND ASSEMBLY
M1351007200211

CAUTION
Take care not to contact the parts or tools to the
caliper because the paint of caliper will be
scratched. And if there is brake fluid on the cali-
per, wipe out quickly.

14 ± 2 N·m
124 ± 18 in-lb 5 4

6 2
3
5

10
N 7 GREASE: REPAIR KIT GREASE
N 9
8 AC211995 AB

6 10 2
8 9
9 7
7 6
1 5

7
9 5

BRAKE CALIPER KIT SEAL AND BOOT REPAIR KIT SHIM SET

3 4 4
1
3
2
1
2

CLIP SET PAD SET

DISASSEMBLY STEPS DISASSEMBLY STEPS (Continued)


1. PIN 3. PAD AND WEAR INDICATOR
2. PAD ANTI-SQUEAK SPRING ASSEMBLY
4. PAD ASSEMBLY

TSB Revision
35A-34 SERVICE BRAKES
REAR DISC BRAKE ASSEMBLY

DISASSEMBLY STEPS (Continued)


5. SHIM
6. CALIPER BLEEDER
<<A>> 7. PISTON BOOT
<<A>> 8. PISTON
<<B>> 9. PISTON SEAL
10. CALIPER BODY

DISASSEMBLY SERVICE POINTS


CAUTION
Take care not to contact the parts or tools to the caliper
because the paint of caliper will be scratched. And if there
is brake fluid on the caliper, wipe out quickly.
When disassembling the disc brakes, disassemble both sides
(left and right) as a set.
.

<<A>> PISTON BOOT/PISTON REMOVAL


Remove the pistons by pumping in air slowly from the brake
WOODEN PLATE hose connection. Be sure to use a wood block and adjust the
height of the two pistons while so that the pistons protrude
evenly.

AC212149AB

<<B>> PISTON SEAL REMOVAL


CAUTION
Do not use a flat-tipped screwdriver or other tool to pre-
vent damage to inner cylinder.
1. Remove the piston seal with finger tip.
2. Clean the piston surface and inner cylinder with alcohol or
brake fluid DOT 3 or DOT 4.

INSPECTION
M1351007300207
• Check the cylinder for wear, damage or rust.
• Check the piston surface for wear, damage or rust.
• Check the caliper body for wear.
• Check the pad for damage or adhesion of grease, check the
backing metal for damage.
.

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SERVICE BRAKES
SPECIFICATIONS
35A-35
PAD WEAR CHECK
WARNING
• Always replace both brake pads on each wheel as
a set (both front wheels or both rear wheels). Fail-
ure to do so will result in uneven braking, which
may cause unreliable brake operation.
• If there is significant difference in the thickness of
the pads on the left and right sides, check moving
parts.
Measure thickness at the thinnest and most worn area of the
pad.
Replace the pad assembly if pad thickness is less than the limit
value.
Standard value: 9.0 mm (0.35 inch)
Minimum limit: 2.0 mm (0.08 inch)

ACX00690

SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
M1351009600345

ITEMS SPECIFICATIONS
Brake line
Brake tube flare nut 15 ± 2 N⋅m (12 ± 1 ft-lb)
Brake pedal
Brake pedal assembly bolt 12 ± 2 N⋅m (107 ± 17 in-lb)
Brake pedal assembly nut 14 ± 3 N⋅m (124 ± 26 in-lb)
Front disc brake
Brake hose connector bolt 30 ± 5 N⋅m (22 ± 4 ft-lb)
Caliper bleeder 14 ± 2 N⋅m (124 ± 18 in-lb)
Front brake assembly mounting bolt 108 ± 10 N⋅m (80 ± 7 ft-lb)
Master cylinder assembly and brake booster
Brake booster mounting nut 14 ± 3 N⋅m (124 ± 26 in-lb)
Fitting 16 ± 1 N⋅m (12 ± 1 ft-lb)
Master cylinder mounting nut 10 ± 2 N⋅m (89 ± 17 in-lb)
Operating rod jam nut 22 ± 3 N⋅m (16 ± 2 ft-lb)
Rear disc brake
Brake hose connector bolt 15 ± 2 N⋅m (12 ± 1 ft-lb)
Caliper bleeder 14 ± 2 N⋅m (124 ± 18 in-lb)
Rear brake assembly mounting bolt 54 ± 5 N⋅m (40 ± 4 ft-lb)

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35A-36 SERVICE BRAKES
SPECIFICATIONS

GENERAL SPECIFICATIONS
M1351000200317

ITEM SPECIFICATION
Master Type Tandem type
cylinder I.D. mm (in) 26.9 (1.06)
Brake Type Vacuum type, tandem
booster Effective dia. of power 205 + 230 (8 + 9)
cylinder mm (in)
Boosting ratio 4.5 <Brake pedal depressing force: 230 N (51.7 lb)>
Rear wheel hydraulic control method Electronic brake-force distribution (EBD)
Front brakes Type 4-opposed piston, ventilated disc
Disc effective dia. × 263 × 32 (10.4 × 1.3)
thickness mm (in)
Wheel cylinder I.D. mm (in) 40.0 (1.58) × 2, 46.0 (1.81) × 2
Pad thickness mm (in) 10.0 (0.39)
Clearance adjustment Automatic
Rear brakes Type 2-opposed piston, ventilated disc
Disc effective dia. × 252 × 22 (9.9 × 0.9)
thickness mm (in)
Wheel cylinder I.D. mm (in) 40.0 (1.58) × 2
Pad thickness mm (in) 9.0 (0.35)
Clearance adjustment Automatic

SERVICE SPECIFICATIONS
M1351000300392

ITEM STANDARD VALUE LIMIT


Brake pedal height mm (in) 169.1 − 172.1 (6.7 − 6.8) −
Brake pedal free play mm (in) 3 − 8 (0.12 − 0.31) −
Brake pedal to floor board clearance mm (in) 90 (3.5) or more −
Front disc brake pad thickness mm (in) 10.0 (0.39) Minimum 2.0 (0.08)
Front disc brake disc thickness mm (in) 32.0 (1.26) Minimum 29.8 (1.17)
Front disc brake disc run-out mm (in) − 0.03 (0.0012)
Front disc brake drags force N (lb) 69 (15) or less −
Rear disc brake pad thickness mm (in) 9.0 (0.35) Minimum 2.0 (0.08)
Rear disc brake disc thickness mm (in) 22.0 (0.87) Minimum 20.4 (0.80)
Rear disc brake disc run-out mm (in) − 0.03 (0.0012)
Rear disc brake drags force N (lb) 69 (15) or less −
Front wheel bearing axial play mm (in) − 0.05 (0.002)
Rear wheel bearing axial play mm (in) − 0.05 (0.002)
Brake booster push rod protruding amount mm (in) 8.98 − 9.23 (0.354 − −
0.363)

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SERVICE BRAKES
SPECIFICATIONS
35A-37
LUBRICANTS
M1351000400333

ITEM SPECIFIED LUBRICANT


Brake fluid DOT3 or DOT4
Pad assembly Repair kit grease

SEALANT
M1351000500288

ITEM SPECIFIED SEALANT REMARK


Fitting 3MTM AAD Part No. 8661, 8663, 8672, 8678, 8679 or Semi-drying sealant
equivalent

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NOTES

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