SECTION : 4E1

REAR DISC BRAKES

TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 4E1–1 Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4E1–4
Fastener Tightening Specifications . . . . . . . . . . 4E1–1 Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4E1–5
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4E1–1 Hub and Parking Brake Shoe/Backplate . . . . . 4E1–6
Lining Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 4E1–1 UNIT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4E1–10
Rotor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 4E1–1 Caliper Overhaul . . . . . . . . . . . . . . . . . . . . . . . . 4E1–10
MAINTENANCE AND REPAIR . . . . . . . . . . . . . . 4E1–3 GENERAL DESCRIPTION AND SYSTEM
ON–VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . 4E1–3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4E1–12
Shoe and Lining . . . . . . . . . . . . . . . . . . . . . . . . . . 4E1–3 Disc Brake Caliper Assembly . . . . . . . . . . . . . . 4E1–12

SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Application NSm Lb–Ft Lb–In
Brake Hose Inlet Bolt and Ring Seals 32 24 –
Caliper Mounting Bolts 56 41 –
Lower Caliper Mounting Bolt 27 20 –
Parking Brake Shoe Hold–Down Spring As- 4 – 35
sembly Screw
Rotor Detent Screw 4 – 35
Hub Bolts 65 48 –

DIAGNOSIS ROTOR INSPECTION

Brake rotors are manufactured with close tolerances for
thickness variation, flatness, and lateral runout, but pits
and grooves are created in rotors during usage. Lack of
LINING INSPECTION uniformity of the braking surfaces of the rotor can cause
1. Raise and suitably support the vehicle. inadequate braking and a pulsating pedal during braking.
2. Remove the rear wheels. Refer to Section 2E, Tires The surface finish of the rotor is also important because
and Wheels. an unsuitable surface finish can cause pulling and rapid
3. Visually check the brake shoe linings for minimum wear of the brake shoe lining. If a rotor does not meet the
thickness and wear. specification, it should be refinished to specification or re-
4. Measure the thickness. placed. Refinishing of the rotor should only be done with
Important : The minimum discard thickness of the brake precision equipment.
shoe lining is 2 mm (0.08 inch). Thickness variation can be checked by measuring the
5. Install the shoes in axle sets only. thickness of the rotor at four or more points around the cir-
6. Install the rear wheels. Refer to Section 2E, Tires cumference of the rotor. All measurements must be made
and Wheels. at the same distance from the edge of the rotor. A rotor that
7. Lower the vehicle. varies by more than. 1.0 mm (0.04 inch) can cause pedal
4E1 – 2IREAR DISC BRAKES

pulsation and/or front end vibration during braking. Thick- 2. To preserve wheel balance, mark the relative posi-
ness can be measured with a commercially available mi- tions of the wheel and hub, and remove the rear
crometer and should be 10 mm(0.39 inch) or over. wheel.
3. Fasten the brake rotor to the wheel hub.
4. Mount a dial indicator on the brake caliper.
5. Place the indicator tip approximately 10 mm (0.39
inch) from the outer edge of the brake rotor, per-
pendicular to the disc and under slight preload. Ob-
serve the indicator gauge while rotating the rotor.
6. After measuring is completed, remove the dial indi-
cator and the wheel nuts.
7. If necessary, refinish the rotor with precision equip-
ment. Measure the runout again after refinishing. If
the runout exceeds 0.8 mm (0.03 inch) after refin-
ishing, the rotor should be replaced.
8. Align the marks that were made before wheel re-
moval, and install the rear wheel.
9. Lower the vehicle.

Light scoring of the rotor surfaces is acceptable if it does

not exceed 0.40 mm (0.016 inch) in depth. Scoring mea-
surements can be made with a commercially available
brake micrometer.
Lateral runout cannot exceed 0.8 mm (0.03 inch). If lateral
runout exceeds the specification, make sure that there is
no dirt between the rotor and the hub and that hub–to–ro-
tor contact surfaces are smooth and free from burrs. Use
a commercially available dial indicator to check the lateral
runout according to the following procedure.
1. Position the shift lever in NEUTRAL and raise the
vehicle.

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MAINTENANCE AND REPAIR

ON–VEHICLE SERVICE

SHOE AND LINING

Removal Procedure

1. Raise and suitably support the vehicle.

2. Remove the rear wheels. Refer to Section 2E, Tires
and Wheels.
3. Remove the lower caliper guide pin bolt.
Important : Caliper removal is not necessary to service
the brake pads.

4. Pivot the caliper upward.

5. Remove the brake shoes.

Installation Procedure

1. Measure the minimum brake shoe lining thickness.

Refer to ”Lining Inspection” in this section.
2. Install the brake shoes into the caliper.
3. Push the piston inward, if needed.

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Notice : Avoid damaging the piston seal when the piston

housing is pulled down.
4. Pivot the caliper downward and install the bolt.
Tighten
Tighten the lower caliper mounting bolt to 27 NSm (20
lb–ft).
5. Install the rear wheels. Refer to Section 2E, Tires
and Wheels.
6. Lower the vehicle.

CALIPER
Removal Procedure

1. Raise and suitably support the vehicle.

2. Mark the position of the rear wheels relative to the
wheel hubs and remove the wheels. Refer to Sec-
tion 2E, Tires and Wheels.
3. Remove the bolt and the ring seals that attach the
brake hose inlet fitting to the caliper.

4. Disconnect the brake hose. Plug the openings in

the caliper and the brake hose to prevent fluid loss
or contamination.
5. Remove the caliper mounting bolts from the steer-
ing knuckle.
6. Remove the caliper.

Installation Procedure

1. Install the caliper with the mounting bolts.

Tighten
Tighten the caliper mounting bolts to 56 NSm (41 lb–
ft).

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2. Connect the brake hose with the bolt and ring

seals.
Tighten
Tighten the brake hose inlet bolt and ring seals to 32
NSm (24 lb–ft).
3. Install the rear wheels. Refer to Section 2E, Tires
and Wheels.
4. Lower the vehicle.
5. Fill the master cylinder to the proper level with
clean brake fluid.
6. Bleed the caliper. Refer to Section 4F, Antilock
Brake System and Traction Control System.

ROTOR
Removal Procedure

1. Remove the caliper. Refer to ”Caliper” in this sec-

tion.
2. Remove the brake shoes.
3. Remove the caliper mounting bracket.

4. Remove the rotor detent screw.

5. Remove the rotor.

Installation Procedure

Important : To guarantee uniform braking, always refinish

both rotors even if only one rotor is defective.
1. Install the rotor on the front wheel hub and install
the detent screw.
Tighten
Tighten the rotor detent screw to 4 NSm (35 lb–in)

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2. Apply a few drops of thread–locking compound to

the caliper bracket mounting bolts and install the
caliper bracket.
Tighten
Tighten the caliper bracket mounting bolts to 56 NSm
(41 lb–ft).
3. Install the brake shoes and the caliper. See ”Cali-
per” in this section.

HUB AND PARKING BRAKE

SHOE/BACKPLATE
Removal Procedure

1. Remove the caliper mounting bracket.

2. Remove the rotor detent screw.

3. Remove the rotor.

4. Remove the rear ABS sensor connector.

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5. Remove the hub bolts and hub.

6. Remove the upper return spring, lower return spring

and adjuster assembly.

7. Remove the retaining spring plate, spring and re-

taining spring pin.
8. Remove the parking brake shoe.

9. Remove the parking brake cable pin and cable from

the backing plate.

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Installation Procedure

1. Install the parking brake cable to the backing plate

and lock the pin.

2. Install the retaining spring pin, parking brake shoe,

retaining spring and retaining spring plate.

3. Install the adjuster assembly, lower return spring

and upper return spring.

4. Install the hub with bolts.

Tighten
Tighten the hub bolts to 65 NSm (48 lb–ft).

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5. Connect the ABS sensor connector.

6. Install the rotor with detent screw.

Tighten
Tighten the rotor detent screw to 4 NSm (35 lb–in).

7. Install the caliper mounting bracket with bolts.

Tighten
Tighten the caliper bracket mounting bolts to 56 NSm
(41 lb–ft).
8. Install the wheel.

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4E1 – 10IREAR DISC BRAKES

UNIT REPAIR

CALIPER OVERHAUL
1. Remove the caliper. Refer to ”Caliper” in this sec-
tion.
CAUTION : Do not attempt to catch the piston when
attempting to remove the piston with compressed air.
The piston will pop out of its bore with enough force
to damage a hand or fingers.
Important : When removing the caliper piston with com-
pressed air, place some rolled–up shop towels beneath
the caliper to prevent damage to the piston.
2. Apply unlubricated compressed air at the hose inlet
of the caliper.

3. Remove the piston from its bore and remove the

piston dust seal.
4. Remove the inner seal from the bore. Avoid
scratching the bore.

5. Remove the bleeder valve dust cap and the bleeder

valve.

Assembly Procedure

Important : Do not use a hone or any other procedure to

remove material from the caliper bore or the piston.
1. Clean all parts in denatured alcohol or brake fluid.
Dry the parts with unlubricated compressed air and
blow out all passages in the housing and the bleed-
er valve.
2. Inspect the piston and caliper for scoring, nicks, or
corrosion. Replace any components which show
these conditions.

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3. Install the bleeder valve and the dust cap.

3. Lubricate a new piston inner seal with brake fluid.

4. Install the piston inner seal into the groove in the
caliper bore.

5. Install the piston dust seal in its groove.

6. Lubricate the piston with brake fluid.
7. Push the piston inward until it is properly seated.
Make sure that the dust seal is in the correct
groove in the piston and the caliper.
8. Reinstall the caliper. Refer to ”Caliper” in this sec-
tion.
9. Bleed the brake system. Refer to Section 4F, Anti–
lock Brake System.

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S Replace all components included in the repair kits

GENERAL DESCRIPTION used to service the caliper.
S Lubricate the rubber parts with clean brake fluid to
AND SYSTEM OPERATION ease assembly.
S Do not use lubricated shop air on brake parts, as
damage to the rubber components may result.
DISC BRAKE CALIPER ASSEMBLY S If any hydraulic component is removed or discon-
The caliper has a single bore and is mounted to the steer- nected, it may be necessary to bleed all or part of
ing knuckle with two mounting bolts. Hydraulic pressure, the brake system. Refer to Section 4F, Anti–lock
created by applying the brake pedal, is converted by the Brake System.
caliper to a stopping force. This force acts equally against S Replace the shoes in axle sets only.
the piston and the bottom of the caliper bore to move the S The torque values specified are for dry, unlubri-
piston outward and to slide the caliper inward, resulting in cated fasteners.
a clamping action on the rotor. This clamping action forces S Perform the service operations on a clean bench,
the linings against the rotor, creating friction to stop the ve- free from oily material.
hicle.

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