Brake RM808U
Brake RM808U
Brake RM808U
ABS ACTUATOR
BR0LL-05
COMPONENTS
15 (155, 11)
13 (130, 9)
Holder
ABS Actuator
Cushion
Cushion
19 (195, 14)
Actuator Bracket
Air Cleaner Assembly
19 (195, 14)
ECU
Spring Plate
Actuator
DISASSEMBLY
1. DISCONNECT CONNECTOR
2. REMOVE ECU
(a) Using a T20 torx wrench, loosen the 6 screws.
Torque: 3.0 N·m (31 kgf·cm, 27 in.·lbf)
NOTICE:
At the time of reassembly, tighten the screws according to
the order shown on the left.
W03326
(b) Remove the ECU and spring plate from the actuator.
NOTICE:
Protect the actuator in order to prevent sealing surface
from getting dirty and causing damage on the valve body.
If the dirt and the like are stuck to the sealing surface, use
plastic tools or soft objects to remove the dirt. Do not use
chemical solvents.
INSTALLATION
Installation is in the reverse order of removal (See page BR-48 ).
HINT:
After installation, fill the brake reservoir with brake fluid, bleed brake system (See page BR-4 ).
Check for fluid leaks.
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page BR-49 ).
2 REMOVAL
1. REMOVE AIR CLEANER ASSEMBLY
1
2. DISCONNECT CONNECTOR
Pull out the release bar, and disconnect the connector.
F09732
F09733
COMPONENTS
15 (155, 11)
15 (155, 11)
Air Cleaner Assembly
ABS & VSC Actuator Assembly
19 (195, 14)
19 (195, 14)
Holder
13 (130, 9)
Holder
13 (130, 9)
Cushion
Cushion
Actuator Bracket
INSTALLATION
Installation is in the reverse order of removal (See page BR-54 ).
HINT:
After installation, fill the brake reservoir with brake fluid, bleed brake system (See page BR-4 ).
Check for fluid leaks.
ON-VEHICLE INSPECTION
1. CONNECT TOYOTA HAND-HELD TESTER:
(a) Connect the TOYOTA hand-held tester to the DLC3.
(b) Start the engine and run it at idle.
(c) Select the ACTIVE TEST mode on the TOYOTA hand-
held tester.
DLC3 D07259
Please refer to the TOYOTA hand-held tester operator’s
manual for further details.
2. INSPECT ACTUATOR MOTOR OPERATION
(a) With the motor relay ON, check the actuator motor opera-
tion noise.
(b) Turn the motor relay OFF.
(c) Depress the brake pedal and hold it for about 15 seconds.
Check that the brake pedal cannot be depressed.
(d) With the motor relay ON, check that the pedal does not
pulsate.
NOTICE:
Do not keep motor relay ON for more than 5 seconds con-
tinuously. When operating it continuously, set the interval
of more than 20 seconds.
(e) Turn the motor relay OFF and release the brake pedal.
3. INSPECT RIGHT FRONT WHEEL OPERATION
NOTICE:
Never turn ON the solenoid which is not described below.
(a) With the brake pedal depressed, perform the following
operations.
(b) Turn the SFRH and SFRR solenoid ON simultaneously,
and check that the pedal cannot be depressed.
NOTICE:
Do not keep solenoid ON for more than 10 seconds contin-
uously. When operating it continuously, set the interval of
more than 20 seconds.
(c) Turn the SFRH and SFRR solenoid OFF simultaneously,
and check that the pedal can be depressed.
(d) Turn the motor relay ON, and check that the pedal re-
turns.
NOTICE:
Do not keep motor relay ON for more than 5 seconds con-
tinuously. When operating it continuously, set the interval
of more than 20 seconds.
(e) Turn the motor relay OFF and release the brake pedal.
4. INSPECT OTHER WHEEL OPERATION
As in the same procedure, check the solenoids of other wheels.
HINT:
Left front wheel: SFLH, SFLR
Right rear wheel: SRRH, SRRR
Left rear wheel: SRLH, SRLR
5. CLEAR DTC (See page DI-252 )
2001 AVALON (RM808U)
REMOVAL
1. REMOVE AIR CLEANER ASSEMBLY
2. DISCONNECT ABS & VSC ACTUATOR CONNECTOR
F09736
COMPONENTS
Air Cleaner with Air Cleaner Hose
Return Spring
Pin
Vacuum Hose
Wave Washer
Master Cylinder
15 (155, 11)
Clip
2-way Clevise
Level Warning Switch 12 (260, 19)
13 (130, 9)
Connetor
Gasket
13 (130, 9) Brake Booster Assembly
Lower LH Instrument
Panel Insert
INSTALLATION
1. INSTALL BRAKE BOOSTER
(a) Install the booster and a new gasket.
(b) Install the clevis to the operating rod.
(c) Install and torque the booster installation nuts.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
(d) Install the clevis pin into the clevis and brake pedal, and
install the clip to the clevis pin.
(e) Install the pedal return spring.
F05420
(b) Turn the SST upside down, and set it on the booster.
SST
SST 09737-0001 1
(c) Measure the clearance between the booster push rod
and pin head (SST).
Clearance: 0 mm (0 in.)
F05422
(d) Using SST, adjust the booster push rod length until the
push rod lightly touches the pin head.
SST 09737-00020
3. w/ VSC:
INSTALL PRECHARGE PUMP ASSEMBLY (See page
BR-58 )
4. INSTALL MASTER CYLINDER (See page BR-20 )
SST 5. CONNECT VACUUM HOSE TO BRAKE BOOSTER
F05421 6. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND
BLEED BRAKE SYSTEM (See page BR-4 )
7. CHECK FOR LEAKS
8. CHECK AND ADJUST BRAKE PEDAL (See page
BR-6 )
9. INSTALL NO. 2 HEATER TO REGISTER DUCT, LOWER
LH INSTRUMENT PANEL INSERT AND LOWER NO. 1
INSTRUMENT PANEL (See page BO-87 )
10. DO OPERATIONAL CHECK (See page BR-21 )
ON-VEHICLE INSPECTION
1. OPERATING CHECK
(a) Depress the brake pedal several times with the engine off
and check that there is no change in the pedal reserve
distance.
(b) Depress the brake pedal and start the engine. If the pedal
BR2237
goes down slightly, operation is normal.
REMOVAL
1. REMOVE AIR CLEANER COVER WITH AIR CLEANER
HOSE
2. REMOVE MASTER CYLINDER (See page BR-15 )
3. w/ VSC:
REMOVE PRECHARGE PUMP ASSEMBLY (See page
BR-57 )
4. DISCONNECT VACUUM HOSE FROM BRAKE
BOOSTER
5. REMOVE LOWER NO. 1 INSTRUMENT PANEL, LOW-
ER LH INSTRUMENT PANEL INSERT AND NO. 2
HEATER TO REGISTER DUCT (See page BO-87 )
F06431
COMPONENTS
3-way
Master Cylinder
15 (155, 11)
2-way
13 (130, 9)
13 (130, 9)
Brake Booster
15 (155, 11)
w/o VSC:
Cap
Strainer
O-Ring
Grommet
Grommet
Gasket
Stopper Bolt
10 (100, 7)
w/ VSC:
Cap
Strainer
Snap Ring
O-Ring
Straight Pin
Grommet
Grommet
Cylinder Body
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
Lithium soap base giycol grease F09748
DISASSEMBLY
1. REMOVE RESERVOIR
(a) Remove the set screw and pull out the reservoir.
Torque: 1.7 N·m (17.5 kgf·cm, 15.2 in.·lbf)
(b) Remove the cap and strainer from the reservoir.
2. REMOVE 2 GROMMETS
3. w/o VSC:
PLACE CYLINDER IN VISE
4. w/o VSC:
Soft Jows
REMOVE PISTON STOPPER BOLT
Using a screwdriver, push the pistons in all the way and remove
the piston stopper bolt and gasket.
HINT:
Tape the screwdriver tip before use.
Torque: 10 N·m (100 kgf·cm, 7 ft·lbf)
F09715
5. w/o VSC:
REMOVE 2 PISTONS AND SPRINGS
(a) Push in the piston with a screwdriver and remove the
snap ring with snap ring pliers.
HINT:
Tape the screwdriver tip before use.
(b) Remove the No. 1 piston and spring by hand, pulling
Soft Jows straight out, not at an angle.
F09716 NOTICE:
If pulled out and install at an angle, there is a possibil-
ity that the cylinder bore could be damaged.
At the time of reassembly, be careful not to damage
the rubber lips on the pistons.
(c) Place a rag and 2 wooden blocks on the work table, and
lightly tap the cylinder flange against the block edges until
the No. 2 piston drops out of the cylinder.
HINT:
Make sure that the distance (A) from the rag to the top of the
blocks is at least 100 mm (3.94 in.).
A
R12236
6. w/ VSC:
REMOVE 2 PISTONS AND SPRINGS
(a) Push in the piston with a screwdriver, and remove the
straight pin by turning over the cylinder body.
HINT:
Tape the screwdriver tip before use.
(b) Remove the 2 piston and springs by hand, pulling straight
out, not at an angle.
F09717 NOTICE:
If pulled out and installed at an angle, there is a possi-
bly that the cylinder bore could be damaged.
F09718
INSPECTION
HINT:
Clean the disassembled parts with compressed air.
1. INSPECT CYLINDER BORE FOR RUST OR SCORING
2. INSPECT CYLINDER FOR WEAR OR DAMAGE
If necessary, clean or replace the cylinder.
INSTALLATION
Installation is in the reverse order of removal (See page BR-15 ).
HINT:
Before installation, adjust length of brake booster push rod (See page BR-24 ).
After installation, fill the brake reservoir with brake fluid, bleed brake system (See page BR-4 ), and
check for leaks.
Check and adjust brake pedal (See page BR-6 ).
REASSEMBLY
Reassembly is in the reverse order of disassembly (See-page BR-16 ).
NOTICE:
Apply lithium soap base glycol grease to the rubber parts indicated by the arrows (See page
BR-13 ).
REMOVAL
1. REMOVE AIR CLEANER COVER WITH AIR CLEANER
HOSE
2. TAKE OUT FLUID WITH SYRINGE
NOTICE:
Do not let brake fluid remain on a painted surface. Wash it
off immediately.
3. DISCONNECT LEVEL WARNING SWITCH CONNEC-
TOR
4. w/ VSC:
DISCONNECT RESERVOIR HOSE
F09714
BLEEDING
HINT:
If any work is done on the brake system or if air in the brake lines
is suspected, bleed the air from the system.
NOTICE:
Do not let brake fluid remain on a painted surface. Wash it
off immediately.
F09707
F09708
(c) Block off the outlet plugs with your fingers, and release
the brake pedal.
(d) Repeat (b) and (c) 3 or 4 times.
F09709
6. w/ VSC:
SST BLEED PRECHARGE PUMP
CAUTION:
When repairing the brake master cylinder or precharge
pump, bleed the precharge pump of the air.
(a) Install the SST to the reservoir.
SST 09992-00242, 09992-00350
(b) Using SST, apply pressure to the reservoir.
F10182 Pressure: 98.1 kpa (1.0 kgf/cm2, 14.2 psi)
(c) Disconnect the precharge pump connector.
1 2
(d) Connect ML+ (2) terminal to the battery positive (+) and
ML- (1) terminal to the battery negative (-), and activate
the precharge pump about 20 seconds.
(e) Remove the SST from the reservoir.
(f) Connect the vinyl tube to the front brake caliper RH, and
(-) (+) loosen the bleeder plug.
(g) Activate the precharge pump again until there are no
more air bubbles in the fluid.
F07901 Bleeder plug tightening torque:
8.3 N·m (85 kgf·cm, 74 in.·lbf)
(h) Connect the precharge pump connector.
7. CHECK FLUID LEVEL IN RESERVOIR
Check the fluid level and add fluid if necessary.
Fluid: SAE J1703 or FMVSS No. 116 DOT3
COMPONENTS
13 (130, 9)
13 (130, 9)
Collar Bushing
Cushion Plate
Bushing
Clevis Pin
39 (400, 29)
Clip
Wave Washer
Return Spring
BRAKE PEDAL
Stop Light Switch BR0KI-04
ON-VEHICLE INSPECTION
1. CHECK PEDAL HEIGHT
Pedal height from asphalt sheet:
153.3 - 163.3 mm (6.035 - 6.429 in.)
If the pedal height is incorrect, adjust it.
2. IF NECESSARY, ADJUST PEDAL HEIGHT
Push Rod (a) Remove the lower No. 1 instrument panel and lower LH
instrument panel insert (See page BO-87 ).
(b) Disconnect the connector from the stop light switch.
(c) Loosen the stop light switch lock nut and remove the stop
light switch.
(d) Loosen the push rod lock nut.
(e) Adjust the pedal height by turning the pedal push rod.
Pedal Height
(f) Tighten the push rod lock nut.
Torque: 25 N·m (260 kgf·cm, 19 ft·lbf)
(g) Install the stop light switch.
R00954
(h) Connect the connector to the stop light switch.
(i) Push the brake pedal in 5 - 15 mm (0.20 - 0.59 in.), turn
the stop light switch to lock the nut in the position where
the stop light goes off.
(j) After installation, push the brake pedal in 5 - 15 mm (0.20
- 0.59 in.), check that stop light lights up.
(k) After adjusting the pedal height, check the pedal freeplay.
(l) Install the lower LH instrument panel insert and lower No.
1 instrument panel (See page BO-87 ).
BRAKE SYSTEM
BR0MH-01
PRECAUTION
Care must be taken to replace each part properly as it could affect the performance of the brake
system and result in a driving hazard. Replace the parts with parts of the same part number or
equivalent.
It is very important to keep parts and the area clean when repairing the brake system.
If the vehicle is equipped with a mobile communication system, refer to the precaution in the
IN section.
COMPONENTS
107 (1,090, 79)
Caliper
Torque Plate 29 (300, 22)
34 (350, 25)
Disc
Bleeder Plug
8.3 (85, 74 in.·lbf)
29 (300, 22)
Gasket
Sliding Pin
Sliding Bushing
Piston
Dust Boot
Set Ring
Piston Seal
Boot
DISASSEMBLY
1. REMOVE SET RING AND CYLINDER BOOT
Using a screwdriver, remove the set ring and cylinder boot from
the caliper.
R00121
2. REMOVE PISTON
(a) Place a piece of cloth or similar, between the piston and
the caliper.
(b) Use compressed air to remove the piston from the cylin-
der.
CAUTION:
Do not place your fingers in front of the piston when using
compressed air.
R00122
R00123
INSPECTION
1. MEASURE PAD LINING THICKNESS
Using a ruler, measure the pad lining thickness.
Standard thickness: 11.0 mm (0.433 in.)
Minimum thickness: 1.0 mm (0.039 in.)
Replace the pad if the pad’s thickness is at the minimum thick-
ness or less, or if the pad has severe, uneven wear.
F06988
F06395
INSTALLATION
Installation is in the reverse order of removal (See page BR-29 ).
HINT:
After installation, fill the brake reservoir with brake fluid, bleed brake system (See page BR-4 ).
Check for fluid leaks.
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page BR-30 ).
NOTICE:
Apply lithium soap base glycol grease to the parts indicated by arrows (See page BR-28 ).
REMOVAL
1. REMOVE FRONT WHEEL
Remove the wheel and temporarily fasten the disc with hub
nuts.
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)
2. DISCONNECT FLEXIBLE HOSE
(a) Remove the union bolt and 2 gaskets from the caliper,
then disconnect the flexible hose from the caliper.
R02840
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
HINT:
At the time of installation, install the flexible hose lock securely
in the lock hole in the caliper.
(b) Use a container to catch the brake fluid as it drains out.
3. REMOVE CALIPER
(a) Remove the 2 installation bolts.
Torque: 34 N·m (350 kgf·cm, 25 ft·lbf)
(b) Remove the caliper from the torque plate.
4. REMOVE 2 BRAKE PADS WITH ANTI- SQUEAL
SHIMS
5. REMOVE 2 PAD SUPPORT PLATES
COMPONENTS
34 (350, 25)
Anti-squeal Shim
Outer Pad
Inner Pad
REPLACEMENT
1. REMOVE FRONT WHEEL
2. INSPECT PAD LINING THICKNESS
Check the pad thickness through the caliper inspection hole
and replace the pads if it is not within the specification.
Minimum thickness: 1.0 mm (0.039 in.)
3. LIFT UP CALIPER
(a) Remove the bolt and flexible hose from the shock absorb-
F06984
er bracket.
(b) Remove the bottom side installation bolt.
(c) Lift up the caliper and suspend it securely.
HINT:
Do not disconnect the flexible hose from the caliper.
4. REMOVE 2 BRAKE PADS WITH 4 ANTI- SQUEAL
SHIMS
5. REMOVE PAD WEAR INDICATOR PLATE
6. REMOVE 2 PAD SUPPORT PLATES
NOTICE:
The support plates can be used again provided that they
have sufficient rebound, no deformation, cracks or wear,
and have had all rust, dirt and foreign particles cleaned off.
7. CHECK DISC THICKNESS AND RUNOUT (See page
BR-31 )
8. INSTALL 2 PAD SUPPORT PLATES
COMPONENTS
Sensor Rotor
INSTALLATION
Installation is in the reverse order of removal (See page BR-60 ).
AFTER INSTALLATION, CHECK SPEED SENSOR SIGNAL (See page DI-252 or DI-212 )
REMOVAL
1. DISCONNECT SPEED SENSOR CONNECTOR
(a) Remove the fender liner.
(b) Disconnect the speed sensor connector.
R00327
F09739
PARKING BRAKE
BR0LG-03
COMPONENTS
Adjuster
Guide Plate
Spring
Shoe Strut
47 (475, 34)
Shoe Return Spring
Pin
Shim
C-washer
Parking Brake 47 (475, 34)
Lever
Cap
Pin
Adjuster Shoe Hold-down Spring
Front Shoe Rear Disc Brake
Rear Shoe Assembly
Tension Spring
Cap
Plug
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part Disc
High temperature grease
F09730
DISASSEMBLY
1. REMOVE REAR WHEEL
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)
2. REMOVE REAR DISC BRAKE ASSEMBLY
(a) Remove the 2 mounting bolts and remove the disc brake
assembly.
Torque: 47 N·m (475 kgf·cm, 34 ft·lbf)
(b) Suspend the disc brake securely. Ensure that the hose is
W04053
not stretched.
3. REMOVE DISC
Release the parking brake pedal, and remove the disc.
HINT:
If the disc cannot be removed easily, turn the shoe adjuster until
the wheel turns freely.
R00309
R00310
INSPECTION
1. INSPECT DISASSEMBLED PARTS
Inspect the disassembled parts for wear, rust or damage.
2. MEASURE BRAKE SHOE LINING THICKNESS
Using a ruler, measure the thickness of the shoe lining.
Standard thickness: 2.0 mm (0.079 in.)
Minimum thickness: 1.0 mm (0.039 in.)
If the lining thickness is at the minimum thickness or less, or if
R00311
there is severe, uneven wear, replace the brake shoe.
BR0828
R00313
REASSEMBLY
Reassembly is in the reverse order of disassembly (See
page BR-44 ).
NOTICE:
Apply high temperature grease to the parts indicated by the
arrows (See page BR-43 ).
1. ADJUST PARKING BRAKE SHOE CLEARANCE
(a) Temporarily install the hub nuts.
(b) Remove the hole plug.
(c) Turn the adjuster and expand the shoes until the disc
locks.
Contract (d) Return the adjuster 8 notches.
(e) Install the hole plug.
2. SETTLING PARKING BRAKE SHOES AND DISC
(a) Depress the parking brake pedal with 147 N (15 kgf, 33
lbf).
Expand (b) Drive the vehicle at about 50 km/h (31 mph) on a safe, lev-
BR0823 el and dry road.
(c) Drive the vehicle for about 400 meters (0.25 mile) in this
condition.
(d) Repeat this procedure 2 or 3 times.
3. RECHECK AND ADJUST PARKING BRAKE PEDAL
TRAVEL (See page BR-9 )
COMPONENTS
61 (620, 45)
Clip
61 (620, 45)
Cushion
INSTALLATION
Installation is in the reverse order of removal (See page BR-1 1).
AFTER INSTALLATION, ADJUST PARKING BRAKE PEDAL TRAVEL (See page BR-6 )
ON-VEHICLE INSPECTION
1. CHECK PARKING BRAKE PEDAL TRAVEL
Slowly depress the parking brake pedal all the way, and count
the number of clicks.
Parking brake pedal travel at 294 N (30 kgf, 66 lbf):
3 - 6 clicks
R00254
If incorrect, adjust the parking brake.
Adjusting Hexagon
2. IF NECESSARY, ADJUST PARKING BRAKE PEDAL
TRAVEL
HINT:
Before adjusting the parking brake, make sure that the rear
brake shoe clearance has been adjusted.
For shoe clearance adjustment, see step 1 on page BR-46 .
(a) Floor shift:
Remove the console box.
Lock Nut No. 4 Cable (b) Column shift:
F09710
(f) Hold the parking brake cable and turn the adjusting hexa-
gon until the pedal travel is correct.
NOTICE:
To prevent the parking brake cable from twisting, always
Red Paint keep the red-painted surface up.
(g) Holding the adjusting hexagon, tighten the lock nut.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
(h) Floor shift:
W03176 Install the console box.
(i) Column shift:
Install the hole cover.
REMOVAL
1. REMOVE LOWER NO. 1 INSTRUMENT PANEL, LOW-
ER LH PANEL INSERT AND NO. 2 HEATER TO REG-
ISTER DUCT (See page BO-87 )
2. RELEASE PARKING BRAKE PEDAL
F09746
F09747
PRECHARGE PUMP
BR159-01
COMPONENTS
Air Cleaner Cover With Air Cleaner Hose
Level Warning Switch Connector
Master Cylinder
19 (195, 14)
3-way
15 (155, 11)
13 (130, 9)
19 (195, 14)
Precharge Pump Assembly
15 (155, 11)
Master Cylinder Pressrue Sensor
81 (830, 60)
Spacer
O-Ring
Precharge Pump
20 (200, 15)
Cushion
Holder
Precharge Pump Bracket
Collar
Cushion
Washer
8.0 (82, 71in.·lbf)
13 (130, 9)
INSTALLATION
Installation is in the reverse order of removal (See page BR-57 ).
HINT:
After installation, fill the brake reservoir with brake fluid, bleed brake system (See page BR-4 ).
Check for fluid leaks.
REMOVAL
1. REMOVE AIR CLEANER CASE WITH AIR CLEANER
HOSE
2. REMOVE MASTER CYLINDER (See page BR-15 )
3. DISCONNECT PRECHARGE PUMP CONNECTOR
F09742
(b) Using SST, disconnect the 2 brake lines from the prechar-
ge pump.
SST 09751-3601 1
Torque:
10 mm nut: 15 N·m (155 kgf·cm, 11 ft·lbf)
12 mm nut: 20 N·m (200 kgf·cm, 15 ft·lbf)
SST
F09743
F09745
COMPONENTS
Disc
Gasket
34 (350, 25)
29 (300, 22)
Plug
Flexble Hose Bleeder Plug
8.3 (85, 74 in.·lbf)
Gasket
Brake Caliper
34 (350, 25)
Piston
47 (475, 34)
Boot
DISASSEMBLY
1. REMOVE CYLINDER BOOT SET RING AND CYL-
INDER BOOT
Using a screwdriver, remove the cylinder boot set ring and cylin-
der boot from the cylinder.
F09726
2. REMOVE PISTON
(a) Place a piece of cloth or similar, between the piston and
caliper.
(b) Use compressed air to remove the piston from the cylin-
der.
CAUTION:
Do not place your fingers in front of the piston when using
compressed air.
F09727
F09728
INSPECTION
1. MEASURE PAD LINING THICKNESS (See page
BR-31 )
Standard thickness: 10.0 mm (0.394 in.)
Minimum thickness: 1.0 mm (0.039 in.)
2. MEASURE DISC THICKNESS
(See step 2 on page BR-31 )
Standard thickness: 12.0 mm (0.472 in.)
Minimum thickness: 10.5 mm (0.413 in.)
3. MEASURE DISC RUNOUT
(See step 3 on page BR-31 )
Maximum disc runout: 0.15 mm (0.0059 in.)
If the disc’s runout is at the maximum value or greater, check the
bearing play in the axial direction and check the axle hub runout
(See page SA-45 ). If the bearing play and axle hub runout are
not abnormal, adjusting the disc runout or grind it on a ”On-Car”
brake lathe.
4. IF NECESSARY, ADJUST DISC RUNOUT
(a) Remove the 2 bolts and torque plate.
(b) Remove the hub nuts and the disc. Reinstall the disc 1/5
of a turn round from its original position on the hub. Install
and torque the hub nuts.
Torque: 103 N·m (1050 kgf·cm, 76 ft·lbf)
Remeasure the disc runout. Make a note of the runout
and the disc’s position on the hub.
(c) Repeat (b) until the disc has been installed on the 3 re-
maining hub positions.
(d) If the minimum runout recorded in (b) and (c) is less than
0.15 mm (0.0059 in.), install the disc in that position.
(e) If the minimum runout recorded in (b) and (c) is greater
than 0.15 mm (0.0059 in.), replace the disc and repeat
step 3.
(f) Install the torque plate and torque the mounting bolts.
Torque: 47 N·m (475 kgf·cm, 34 ft·lbf)
F09729
INSTALLATION
Installation is in the reverse order of removal (See page BR-38 ).
HINT:
After installation, fill the brake reservoir with brake fluid, bleed brake system (See page BR-4 ).
Check for fluid leaks.
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page BR-39 ).
NOTICE:
Apply lithium soap base glycol grease to the parts indicated by the arrows (See page BR-37 ).
REMOVAL
1. REMOVE REAR WHEEL
Remove the wheel and temporarily fasten the disc with hub
nuts.
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)
2. DISCONNECT FLEXIBLE HOSE
(a) Remove the union bolt and 2 gaskets from the caliper,
then disconnect the flexible hose from the caliper.
F09725
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
HINT:
At the time of installation, insert the flexible hose lock securely
in the lock hole in the caliper.
(b) Use a container to catch the brake fluid as it drains out.
3. REMOVE CALIPER
(a) Remove the 2 installation bolts.
Torque: 34 N·m (350 kgf·cm, 25 ft·lbf)
NOTICE:
At the time of installation, insert the sliding pin with sliding
bushing into the bottom side.
(b) Remove the caliper from the torque plate.
4. REMOVE 2 BRAKE PADS WITH ANTI- SQUEAL
SHIMS
5. REMOVE 4 PAD SUPPORT PLATES
NOTICE:
There should be no oil or grease adhering to the friction
surfaces of the pads or disc.
COMPONENTS
34 (350, 35)
Anti-squeal Shim
Outer Pad
Inner Pad
Anti-squeal Shim
REPLACEMENT
1. REMOVE REAR WHEEL
2. INSPECT PAD LINING THICKNESS
Check the pad’s thickness through the caliper inspection hole
and replace pads if not within specification.
Minimum thickness: 1.0 mm (0.039 in.)
F09722
3. LIFT UP CALIPER
(a) Remove the bottom side installation bolt.
(b) Lift up and suspend it securely.
HINT:
Do not disconnect the flexible hose from the caliper.
4. REMOVE 2 BRAKE PADS WITH 4 ANTI- SQUEAL
SHIMS
5. REMOVE 4 PAD SUPPORT PLATES
F09723 NOTICE:
The support plates can be used again provided that they
have sufficient rebound, no deformation, cracks or wear,
and have had all rust, dirt and foreign particles cleaned off.
6. CHECK DISC THICKNESS AND RUNOUT
(See page BR-40 )
7. INSTALL PAD SUPPORT PLATES
Install the 4 pad support plates.
8. INSTALL NEW PADS
NOTICE:
When replacing worn pads, the anti-squeal shims must be
replaced together with the pads.
(a) Apply disc brake grease to both side of the inner
anti-squeal shims (See page BR-37 ).
(b) Install the 2 anti-squeal shims on each pad.
(c) Install 2 pads with the pad wear indicator plates facing
downward.
NOTICE:
There should be no oil or grease adhering to the friction
surfaces of the pads or the disc.
9. INSTALL CALIPER
(a) Draw out a small amount of brake fluid from the reservoir.
(b) Press in the piston with a hammer handle or similar imple-
ment.
HINT:
If the piston is difficult to push in, loosen the bleeder plug and
push in the piston while letting some brake fluid escape.
R10387
F09723
COMPONENTS
INSTALLATION
Installation is in the reverse order of removal (See page BR-63 ).
AFTER INSTALLATION, CHECK SPEED SENSOR SIGNAL (See page DI-252 or DI-212 )
REMOVAL
1. DISCONNECT SPEED SENSOR CONNECTOR
(a) Remove the seat cushion and seatback.
(b) Disconnect the speed sensor connector, and pull out the
sensor wire harness with the grommet.
R00330
R00331
TROUBLESHOOTING
BR0KG-05