Rear Disc Brake: Overhaul

HINT: Overhaul the RH side by the same procedure as the LH side.

1. REMOVE REAR WHEEL 
2. DRAIN BRAKE FLUID 
   NOTE: Wash the brake fluid off immediately if it comes into contact with any painted surface.
3. REMOVE DISC BRAKE PAD KIT REAR (PAD ONLY) 
   1. Remove the clip, anti-rattle spring No.1 and anti-rattle spring No.2.
   2. Remove the 2 pad guide pins and disc brake pads with anti-squeal shims.
   3. Remove the anti-squeal shims from each pad.
4. REMOVE DISC BRAKE CYLINDER ASSY REAR LH 
   1. Remove the union bolt and gasket from the disc brake cylinder, then disconnect the flexible hose from the disc brake cylinder.
      Fig 1: Removing Disc Brake Pad Kit Rear (Pad Only)

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: Gasket has 2 types: 2-piece type and 1-piece type.

   2. Remove the 2 bolts and disc brake cylinder.
      Fig 2: Removing Disc Brake Cylinder

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. REMOVE REAR DISC BRAKE CYLINDER MOUNTING COLLAR 
   1. Remove the 2 cylinder mounting collars from the disc brake cylinder.
6. REMOVE REAR DISC BRAKE BUSH DUST BOOT 
   1. Remove the 3 bush dust boots.
7. REMOVE CYLINDER BOOT 
   1. Using a screwdriver, remove the set ring and cylinder boot.
      Fig 3: Removing Set Ring And Cylinder Boot

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. REMOVE REAR DISC BRAKE PISTON 
   1. Place a piece of cloth or similar, between the piston and the disc brake cylinder.
   2. Use compressed air to remove the piston from the disc brake cylinder.
   CAUTION: Do not place your fingers in front of the piston when using compressed air.
   Fig 4: Removing Rear Disc Brake Piston

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Do not spatter the brake fluid.
9. REMOVE PISTON SEAL 
   1. Using a screwdriver, remove the piston seal from the brake cylinder.
   NOTE: Do not damage the inner cylinder and the cylinder groove.
   Fig 5: Removing Piston Seal

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. REMOVE REAR DISC BRAKE BLEEDER PLUG 
    1. Remove the disc brake bleeder plug cap and bleeder plug from the rear disc brake cylinder.
11. INSPECT BRAKE CYLINDER AND PISTON 
    1. Check the cylinder bore and piston for rust or scoring.
12. INSPECT PAD LINING THICKNESS 
    1. Using a ruler, measure the pad lining thickness.

       Standard thickness: 10.0 mm (0.394 in.) 

       Minimum thickness: 1.0 mm (0.039 in.) 

       Fig 6: Inspecting Pad Lining Thickness

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
13. INSPECT DISC THICKNESS 
    1. Using a micrometer, measure the disc thickness.

       Standard thickness: 9.0 mm (0.354 in.) 

       Minimum thickness: 7.5 mm (0.295 in.) 

       Fig 7: Inspecting Disc Thickness

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
14. REMOVE REAR DISC 
    1. Make matchmarks on the rear disc and the axle hub.
    2. Remove the rear disc.
15. INSTALL REAR DISC 
    1. Aligning the matchmarks, install the rear disc.

    HINT: Select the installation position where the disc has the minimum runout.

    Fig 8: Making Matchmarks On Rear Disc And Axle Hub

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
16. INSPECT DISC RUNOUT 
    1. Temporarily fasten the disc with hub nuts.

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

    2. Using a dial indicator, measure the disc runout 10 mm (0.39 in.) away from the outer edge of the disc.

       Maximum disc runout: 0.15 mm (0.0059 in.) 

    3. If the disc runout is the maximum value or greater, check the bearing play in the axial direction and check the axle hub runout (See ON-VEHICLE INSPECTION ). If the bearing play and axle hub runout are normal, adjust the disc runout or grind it on a "On-car" brake lathe.
       Fig 9: Inspecting Disc Runout

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
17. TEMPORARILY TIGHTEN REAR DISC BRAKE BLEEDER PLUG 
    1. Temporarily tighten the bleeder plug, and install the bleeder plug cap to the disc brake cylinder.
18. INSTALL PISTON SEAL 
    1. Apply the lithium soap base glycol grease on a new piston seal.
    2. Install the piston seal to the disc brake cylinder.
19. INSTALL REAR DISC BRAKE PISTON 
    1. Apply the lithium soap base glycol grease on the piston.
    2. Install the piston to the disc brake cylinder.
    NOTE: Do not screw the piston forcedly in the disc brake cylinder.
20. INSTALL CYLINDER BOOT 
    1. Apply the lithium soap base glycol grease on a new cylinder boot.
    2. Install the cylinder boot to the disc brake cylinder.

       HINT: Install the boot securely to the grooves of the cylinder and piston.

    3. Using a screwdriver, install the set ring.
    NOTE: Do not damage the cylinder boot.
    Fig 10: Installing Cylinder Boot

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
21. INSTALL REAR DISC BRAKE BUSH DUST BOOT 
    1. Apply the lithium soap base glycol grease to seal surface of 3 new bush dust boots.
    2. Install the 3 bush dust boots to the disc brake cylinder.
       Fig 11: Installing Rear Disc Brake Bush Dust Boot

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
22. INSTALL REAR DISC BRAKE CYLINDER MOUNTING COLLAR 
    1. Install the 2 cylinder mounting collars.
23. INSTALL DISC BRAKE CYLINDER ASSY REAR LH 
    1. Install the disc brake cylinder with the 2 bolts.

       Torque: 46.6 N.m (475 kgf.cm, 34 ft.lbf) 

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

       Torque: 29 N.m (296 kgf.cm, 21 ft.lbf) 

    HINT:

    • Gasket has 2 types: 2-piece type and 1-piece type.
    • Install the flexible hose lock securely in the lock hole in the brake cylinder.
      Fig 12: Installing Disc Brake Cylinder Assy Rear LH

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
24. INSTALL DISC BRAKE PAD KIT REAR (PAD ONLY) 
    NOTE: If necessary, replace the anti-squeal shim kit when replacing the brake pad.
    1. Apply disc brake grease to inside of anti-squeal shims, and install the anti-squeal shims on each pad.
    2. Install the inner pad with the pad wear indicator plate facing upward, and install the outer pad.
       NOTE: There should be no oil or grease on the friction surface of the pads and the disc.
    3. Install the 2 pad guide pins.
    4. Install the anti-rattle spring No. 1 anti-rattle spring No. 2 and clip.
       Fig 13: Installing Anti-Rattle Spring No. 1 Anti-Rattle Spring No. 2 And Clip

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
25. FILL RESERVOIR WITH BRAKE FLUID 
26. BLEED MASTER CYLINDER (See  BRAKE FLUID   ) 

    SST 09023-00100

27. BLEED BRAKE LINE (See  BRAKE FLUID   ) 
28. CHECK FLUID LEVEL IN RESERVOIR 
29. CHECK BRAKE FLUID LEAKAGE 
30. INSTALL REAR WHEEL 

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