Rear Brake - Installation

Land Cruiser URJ200 URJ202 GRJ200 VDJ200 - BRAKE REAR

REAR BRAKE - INSTALLATION

  • HINT:
Use the same procedures for the LH side and RH side.
The procedures listed below are for the LH side.
1. INSTALL REAR DISC
Rear Brake - Installation. BRAKE REAR. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Align the matchmarks, and then install the rear disc.

  • HINT:
  • When replacing the rear disc with a new one, select the installation position where the rear disc has the minimum runout.
2. INSTALL PARKING BRAKE SHOE ADJUSTING HOLE PLUG
3. INSTALL REAR DISC BRAKE CYLINDER MOUNTING LH

Install a new boot and a new cylinder slide bush to the rear disc brake cylinder mounting.

  • NOTICE:
  • Install the boot securely to the grooves of the rear disc brake cylinder mounting.
Rear Brake - Installation. BRAKE REAR. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Install the rear disc brake cylinder mounting with 2 new bolts.

  • Torque:
  • 95 N*m{ 969 kgf*cm, 70 ft.*lbf}
4. INSTALL REAR NO. 1 DISC BRAKE PAD SUPPORT PLATE
  • NOTICE:
The pad support plates can be reused if they are securely attached to the cylinder mounting. Therefore, do not remove the pad support plates from the cylinder mounting.
If a pad support plate is removed, replace it with a new one that is supplied with double-sided tape already attached.
Make sure to clean the cylinder mounting contact surface before attaching the pad support plates.

Clean the cylinder mounting surface where the pad support plates will be attached.

Remove the peeling paper from the double-sided tape, and install 2 new pad support plates to the cylinder mounting.

5. INSTALL REAR NO. 2 DISK BRAKE PAD SUPPORT PLATE
  • NOTICE:
The pad support plates can be reused if they are securely attached to the cylinder mounting. Therefore, do not remove the pad support plates from the cylinder mounting.
If a pad support plate is removed, replace it with a new one that is supplied with double-sided tape already attached.
Make sure to clean the cylinder mounting contact surface before attaching the pad support plates.

Clean the cylinder mounting surface where the pad support plates will be attached.

Remove the peeling paper from the double-sided tape, and install 2 new pad support plates to the cylinder mounting.

6. INSTALL REAR DISC BRAKE PAD WEAR INDICATOR PLATE

Install the pad wear indicator plate to the inner side disc brake pad.

7. INSTALL REAR DISC BRAKE ANTI-SQUEAL SHIM KIT

Install the anti-squeal shims to each brake pad.

  • NOTICE:
  • There should be no oil or grease on the friction surfaces of the brake pads and the rear disc.
8. INSTALL REAR DISC BRAKE PAD
  • NOTICE:
When installing the pads, make sure that the No. 1 and No. 2 disc brake pad support plates are securely attached to the cylinder mounting. The pad support plates are attached to the cylinder mounting with double-sided tape.
If a pad support plate is not securely attached to the cylinder mounting, replace it with a new one.

Install the 2 disc brake pads to the disc brake cylinder mounting.

9. INSTALL REAR DISC BRAKE CYLINDER ASSEMBLY LH

Apply lithium soap base glycol grease to the sliding part of the 2 cylinder slide pins.

Rear Brake - Installation. BRAKE REAR. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Install the cylinder with the 2 cylinder slide pins.

  • Torque:
  • 88 N*m{ 897 kgf*cm, 65 ft.*lbf}
10. CONNECT REAR FLEXIBLE HOSE LH
Rear Brake - Installation. BRAKE REAR. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Install a new gasket and connect the flexible hose with the new union bolt.

  • Torque:
  • 30 N*m{ 306 kgf*cm, 22 ft.*lbf}
11. BLEED BRAKE LINE

Turn the ignition switch to ON.

Remove the brake master cylinder reservoir filler cap assembly.

Add brake fluid until the fluid level is between the MIN and MAX lines of the reservoir.

Repeatedly depress the brake pedal and bleed air from the bleeder plug of the front disc brake cylinder RH.

Repeat the step above until the air is completely bled, and then tighten the bleeder plug while depressing the brake pedal.

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

Bleed the air from the bleeder plug of the front disc brake cylinder LH using the same procedure as for the RH side.

With the brake pedal depressed, loosen the bleeder plug of the rear disc brake cylinder RH, continue to hold the brake pedal and allow brake fluid to be drained from the bleeder plug while the pump motor operates.

  • HINT:
Air is bled as the pump motor operates while the brake pedal is being depressed.
Be sure to release the brake pedal to stop the motor after approximately 100 seconds of continuous operation.
As brake fluid is continuously drained while the pump operates, it is not necessary to repeatedly depress the brake pedal.

When there is no more air in the brake fluid, tighten the bleeder plug, and then release the brake pedal.

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

Bleed the air from the bleeder plug of the rear disc brake cylinder LH using the same procedure as for the RH side.

Turn the ignition switch off.

Inspect for brake fluid leaks.

Check and adjust the brake fluid level ().

Clear the DTCs ().

12. ADJUST PARKING BRAKE LEVER TRAVEL

Completely release the parking brake lever.

Loosen the adjusting nut to completely release the parking brake cable.

Rear Brake - Installation. BRAKE REAR. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Temporarily install the hub nuts.

Remove the hole plug.

Rear Brake - Installation. BRAKE REAR. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Insert an adjustment tool into the adjustment hole of the disc. Rotate the adjustment wheel in the "X" direction until the shoes are locked. Then rotate the adjustment wheel in the "Y" direction 8 notches.

Check that the disc can be rotated lightly. If not, rotate the adjustment wheel in the "Y" direction and check again.

Install the hole plug.

Remove the hub nuts.

Rear Brake - Installation. BRAKE REAR. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Turn the adjusting nut until the parking brake lever travel becomes correct.

  • Standard Parking Brake Lever Travel when Pulled with a Force of 200 N (20 kgf, 45 lbf):
  • 5 to 7 clicks

Operate the parking brake lever 3 to 4 times, and check the parking brake lever travel.

  • Standard Parking Brake Lever Travel when Pulled with a Force of 200 N (20 kgf, 45 lbf):
  • 5 to 7 clicks

Check whether the parking brake drags or not.

When operating the parking brake lever, check that the brake warning light comes on.

  • Standard Condition:
  • The brake warning light always illuminates at the first click.
13. INSTALL PARKING BRAKE SHOE ADJUSTING HOLE PLUG
14. INSTALL REAR WHEEL
  • Torque:
  • for Aluminum Wheel:
  • 131 N*m{ 1336 kgf*cm, 97 ft.*lbf}
  • for Steel Wheel:
  • 209 N*m{ 2131 kgf*cm, 154 ft.*lbf}