Rear Brake Reassembly

Apply lithium soap base glycol grease to 2 new cups and the 2 pistons.

Install the 2 cups to the 2 pistons.

Install the compression spring and 2 pistons to the cylinder.

Install 2 new cylinder dust boots to the cylinder.

Temporarily install the bleeder plug to the cylinder.

HINT:

The bleeder plug will be tightened to a torque specification in the "BLEED AIR FROM BRAKE LINE" procedures.

Install the cap to the bleeder plug.

Install the cylinder with the 2 bolts.

Torque:

12 N*m{117 kgf*cm, 8 ft.*lbf}

Using a union nut wrench, connect the brake line.

Torque:

15 N*m{155 kgf*cm, 11 ft.*lbf}

NOTICE:

Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (Toyota Fortuner RM000000UYX010X.html).

Apply high temperature grease to the surface of the backing plate where the shoe will be attached.

Apply high temperature grease to the anchor block plate and cable setting area.

Using needle-nose pliers, install the lever with a new C-washer.

Using needle-nose pliers, connect the No. 3 parking brake cable to the parking brake shoe lever.

Install the strut set and return spring to the shoe.

Attach the support clip to the exposed threads of the strut set.

NOTICE:

The support clip should not contact the adjuster nut.

Using needle-nose pliers, hook the support clip around the spring.

NOTICE:

Be careful not to damage the spring.

Install the front and rear brake shoes.

Move one of the shoes upward and install the shoe tension spring.

Install the shoe front or rear side to the cylinder. Then install the other side of the shoe to the other side of the cylinder.

HINT:

After one side of the shoe is installed to the cylinder, hold that side of the shoe steady. Then widen the opening of the shoe by pulling the other side of the shoe outward and install it to the other side of the cylinder.

NOTICE:

Be careful not to damage the cylinder dust boot.

Using pliers, install the front brake shoe, rear brake shoe, pins and shoe hold down springs.

Using needle-nose pliers, install the lever and lever tension spring.

Check that each part is installed properly.

Measure the inside diameter of the drum and the diameter of the shoes. Check that the difference between the diameters is the standard shoe clearance.

Standard shoe clearance:

0.6 mm (0.0236 in.)

NOTICE:

There should be no oil or grease on the contact surfaces of the shoe lining and drum.

Using a union nut wrench, disconnect the 2 brake lines from the master cylinder.

Slowly depress and hold the brake pedal.

Cover the outer holes with your fingers, and release the pedal.

Repeat the 2 previous steps 3 or 4 times.

Using a union nut wrench, connect the 2 brake lines to the master cylinder.

Torque:

15 N*m{155 kgf*cm, 11 ft.*lbf}

NOTICE:

Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (Toyota Fortuner RM000000UYX010X.html).

Using a union nut wrench, disconnect the 2 brake lines from the master cylinder.

Slowly depress and hold the brake pedal.

Cover the outer holes with your fingers, and release the pedal.

Repeat the 2 previous steps 3 or 4 times.

Using a union nut wrench, connect the 2 brake lines to the master cylinder.

Torque:

15 N*m{155 kgf*cm, 11 ft.*lbf}

NOTICE:

Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (Toyota Fortuner RM000000UYX010X.html).

Remove the bleeder plug cap.

Connect a vinyl tube to the bleeder plugs.

Depress the brake pedal several times, and then loosen the bleeder plug with the pedal depressed.

When fluid stops coming out, immediately tighten the bleeder plug. Then release the pedal.

Repeat the 2 previous steps until all the air in the brake fluid is gone.

Tighten the bleeder plug.

Torque:

11 N*m{110 kgf*cm, 8 ft.*lbf}for front brake

10 N*m{102 kgf*cm, 7 ft.*lbf}for rear brake

Install the cap.

Bleed air from the brake line for each wheel by repeating the above procedures.

Remove the bleeder plug cap.

Connect a vinyl tube to the bleeder plugs.

Depress the pedal several times, and then loosen the bleeder plug with the pedal depressed.

When fluid stops coming out, immediately tighten the bleeder plug. Then release the pedal.

Repeat the 2 previous steps until all the air in the brake fluid is gone.

Tighten the bleeder plug.

Torque:

for front brake:

11 N*m{110 kgf*cm, 8 ft.*lbf}

for rear brake:

10 N*m{102 kgf*cm, 7 ft.*lbf}

Install the cap.

Bleed air from the brake line for each wheel by repeating the above procedures.

Remove the bleeder plug cap.

Connect the vinyl tube to the bleeder plug.

Depress the clutch pedal several times, and then loosen the bleeder plug with the pedal depressed.

At the point when fluid stops coming out, tighten the bleeder plug, and then release the clutch pedal.

Repeat the previous 2 steps until all the air in the fluid is completely bled out.

Tighten the bleeder plug.

Torque:

11 N*m{112 kgf*cm, 8 ft.*lbf}

Install the bleeder plug cap.

Check that all the air has been bled out of the clutch line.

Check the fluid level and add fluid if necessary.

Fluid:

SAE J1703 or FMVSS No. 116 DOT 3

HINT:

Add fluid to a level between the reservoir's MIN and MAX lines.

Check the fluid level.
If the brake fluid level is lower than the MIN line, check for leaks and inspect the disc brake pads. If necessary, refill the reservoir with brake fluid to the MAX line after repair or replacement.

Fluid:

SAE J1703 or FMVSS No. 116 DOT3

Pull the lever upward with a force of approximately 200 N (20 kgf, 45 lbf) and count the number of clicks.

OK:

7 to 9 clicks (without rear brake dragging)

Turn the No. 1 wire adjusting nut until the lever travel is correct.

OK:

7 to 9 clicks (without rear brake dragging)
<Lever pulling force: approximately 200 N (20 kgf, 45 lbf)>

Tighten the lock nut.

Torque:

5.2 N*m{53 kgf*cm, 46 in.*lbf}

HINT:

If further adjustment is necessary, proceed to the next step.