3234 REAR DRUM BRAKE (NUMMI/TMMC MADE)...F42671 F42672 SST F42673 SST F42688 3236 BRAKE REAR DRUM...
Transcript of 3234 REAR DRUM BRAKE (NUMMI/TMMC MADE)...F42671 F42672 SST F42673 SST F42688 3236 BRAKE REAR DRUM...
320IK�03
F49547
Rear Brake Drum Sub�assy
Front Brake Shoe
Tension SpringShoe Hold�down Spring
Pin
Parking Brake ShoeStrut Set LH
Rear Brake Automatic Adjust Lever LH
Return Spring
Cylinder Dust Boot
�
PistonCompression Spring
�
Rear Wheel BrakeCylinder Assy
Pin
10 (102, 7)
15 (155, 11)Bleeder Plug Cap
8.3 (85, 74 in.⋅lbf)Bleeder Plug
N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
High temperature greaseLithium soap base glycol grease
Tension Spring
Shoe Hold�downSpring
Hole Plug
Parking Brake ShoeStrut Set LH
� Non�reusable part
Wheel Cylinder Cup
Wheel Cylinder Cup
Shoe Hold�down Spring Cup
Shoe Hold�downSpring Cup
Rear Brake Shoe
�C�washer
Parking Brake ShoeLever Sub�assy
Cylinder Dust Boot
�
Piston
Adjusting Bolt
32�34�BRAKE REAR DRUM BRAKE (NUMMI/TMMC MADE)
2518Author�: Date�:
2005 COROLLA REPAIR MANUAL (RM1105U)
REAR DRUM BRAKE (NUMMI/TMMC MADE)COMPONENTS
3215E�03
F47455
N·m (kgf·cm, ft·lbf) : Specified torque
� Non�reusable partLithium soap base glycol greaseHigh temperature grease
Wheel Cylinder Cup
Wheel Cylinder Cup
Compression Spring
Parking Brake Shoe Strut Set LH
Hole Plug
Tension Spring
Rear Brake Drum Sub�assy
Rear Brake Automatic Adjust Lever Tension Spring
9.8 (100, 87 in. lbf) Cylinder Dust Boot
Piston
Cylinder Dust Boot
Rear Brake Tube No.4
Piston
Rear Brake Shoe Inspection Plug
Bleeder Plug Cap
Rear Wheel BrakeCylinder Assy
Parking Brake ShoeLever Sub�assy
15 (155, 11)
Pin
Rear Brake Automatic Adjust Lever LH
Shoe Hold�downSpring
Shoe Hold�down Spring Cup
Shoe Hold�downSpring
Shoe Hold�downSpring Cup
Rear Brake Shoe
Front Brake Shoe
�C�washer
8.3 (85, 74 in.⋅lbf)Bleeder Plug
32�42�BRAKE REAR DRUM BRAKE (TMC MADE)
2526Author�: Date�:
2005 COROLLA REPAIR MANUAL (RM1105U)
REAR DRUM BRAKE (TMC MADE)COMPONENTS
3219Q�02
F49548
Matchmarks
F42837
Contract
AutomaticAdjust Lever
F06408
Brake Drum Gauge
F42670
�BRAKE REAR DRUM BRAKE (NUMMI/TMMC MADE)32�35
2519Author�: Date�:
2005 COROLLA REPAIR MANUAL (RM1105U)
OVERHAULHINT:� Use the same procedures for the RH side and LH side.� The procedures listed below are for the LH side.
1. REMOVE REAR WHEEL2. DRAIN BRAKE FLUIDNOTICE:Wash brake fluid off immediately if it adheres to any painted surface.
3. REMOVE REAR BRAKE DRUM SUB�ASSY(a) Put matchmarks on the rear brake drum sub�assy and
the axle hub.(b) Release the parking brake and remove the rear brake
drum sub�assy.HINT:If the brake drum cannot be removed easily, do the followingsteps.
(c) Remove the hole plug and insert a screwdriver throughthe hole in the backing plate, and hold the automatic ad-justing lever away from the adjuster.
(d) Using another screwdriver, contract the brake shoe ad-juster by turning the adjusting bolt.
4. INSPECT BRAKE DRUM INSIDE DIAMETER(a) Using a brake drum gauge or equivalent, measure the in-
side diameter of the drum.Standard inside diameter: 200.0 mm (7.874 in.)Maximum inside diameter: 201.0 mm (7.913 in.)
HINT:If the inside diameter of the brake drum is at the maximum ormore, replace the brake drum sub�assy.
5. REMOVE REAR BRAKE AUTOMATIC ADJUST LEVERLH
(a) Using needle�nose pliers, remove the upper side tensionspring.
(b) Remove the rear brake automatic adjust lever LH from therear brake shoe.
F42671
F42672
SST
F42673
SST
F42688
32�36�BRAKE REAR DRUM BRAKE (NUMMI/TMMC MADE)
2520Author�: Date�:
2005 COROLLA REPAIR MANUAL (RM1105U)
6. REMOVE FRONT BRAKE SHOE(a) Using needle�nose pliers, remove the anchor side ten-
sion spring.
(b) Using SST, remove the cup, shoe hold�down spring andpin.SST 09718�00010
(c) Separate the upper side return spring from the front brakeshoe, and remove the front brake shoe.
7. REMOVE PARKING BRAKE SHOE STRUT SET LH
8. REMOVE REAR BRAKE SHOE(a) Using SST, remove the cup, shoe hold�down spring and
pin.SST 09718�00010
(b) Using needle�nose pliers, separate the parking brakecable No.3 and remove the rear brake shoe.
(c) Remove the upper side return spring from the rear brakeshoe.
F42689
F42690
Ruler
R01564
F42691
�BRAKE REAR DRUM BRAKE (NUMMI/TMMC MADE)32�37
2521Author�: Date�:
2005 COROLLA REPAIR MANUAL (RM1105U)
9. REMOVE REAR BRAKE PARKING BRAKE SHOELEVER SUB�ASSY
(a) Using a screwdriver, remove the C�washer and parkingbrake shoe lever sub�assy.
10. INSPECT REAR DRUM BRAKE SHOE LININGTHICKNESS
(a) Using a ruler, measure the thickness of the shoe lining.Standard thickness: 4.0 mm (0.157 in.)Minimum thickness: 1.0 mm (0.039 in.)
If the lining thickness is at the minimum thickness or less, or ifthere is severe, uneven wear, replace the brake shoe.
11. INSPECT BRAKE DRUM AND REAR DRUM BRAKESHOE LINING FOR PROPER CONTACT
(a) Apply chalk to the inside surface of the drum, then grinddrum on the brake shoe lining to fit.
If the contact between the drum and the shoe lining is improper,repair it using a brake shoe grinder or replace the brake shoeassembly.
12. REMOVE REAR WHEEL BRAKE CYLINDER ASSY(a) Using SST, disconnect the brake line.
SST 09023�00101HINT:Use a container to catch the brake fluid.(b) Remove the bolt and the wheel brake cylinder assy.
13. REMOVE REAR WHEEL CYLINDER CUP KIT(a) Remove the 2 cylinder dust boots from the wheel brake cylinder.(b) Remove the 2 pistons and compression spring.(c) Remove the 2 wheel cylinder cups from each piston.(d) Remove the bleeder plug cap and bleeder plug from the wheel brake cylinder.14. INSPECT BRAKE WHEEL CYLINDER(a) Check the cylinder bore and the piston for rust or scoring.If necessary, replace the wheel brake cylinder assy.
F42692Lithium soap base glycol grease
CapBleeder Plug Boot
CapPiston
Compression Spring
F42691
F49454High temperature grease
F42694
F42688
32�38�BRAKE REAR DRUM BRAKE (NUMMI/TMMC MADE)
2522Author�: Date�:
2005 COROLLA REPAIR MANUAL (RM1105U)
15. INSTALL REAR WHEEL CYLINDER CUP KIT(a) Temporarily tighten the bleeder plug to the wheel brake
cylinder assy, and install the bleeder plug cap.(b) Apply the lithium soap base glycol grease to 2 new wheel
cylinder cups and 2 pistons.(c) Install the 2 wheel cylinder cups on each piston.(d) Install the compression spring and the 2 pistons to the
wheel brake cylinder assy.(e) Install 2 new cylinder dust boots to the wheel brake cylin-
der assy.16. INSTALL REAR WHEEL BRAKE CYLINDER ASSY(a) Install the wheel brake cylinder assy with the bolt.
Torque: 10 N⋅m (102 kgf⋅cm, 7 ft⋅lbf)(b) Using SST, connect the brake tube.
SST 09023�00101Torque: 15 N⋅m (155 kgf⋅cm, 11 ft⋅lbf)
17. APPLY HIGH TEMPERATURE GREASE(a) Apply high temperature grease to the shoe attached sur-
face of the backing plate.
18. INSTALL REAR BRAKE PARKING BRAKE SHOELEVER SUB�ASSY
(a) Using pliers, install the parking brake shoe lever sub�assy with a new C�washer.
19. INSTALL REAR BRAKE SHOE(a) Using needle�nose pliers, connect the parking brake
cable No.3 to the parking brake shoe lever sub�assy.
F42673
SST
F42695High temperature grease
Adjusting Bolt
F42672
SST
F42671
F42670
�BRAKE REAR DRUM BRAKE (NUMMI/TMMC MADE)32�39
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2005 COROLLA REPAIR MANUAL (RM1105U)
(b) Using SST, install the rear brake shoe, the pin, the shoehold down spring and the shoe hold down cup.SST 09718�00010
(c) Connect the upper side return spring to the rear brakeshoe.
20. INSTALL PARKING BRAKE SHOE STRUT SET LH(a) Apply the high temperature grease to the adjusting bolt.(b) Install the parking brake shoe strut set to the rear brake
shoe.21. INSTALL FRONT BRAKE SHOE(a) Install the upper side return spring to the front brake shoe.
(b) Using SST, install the front brake shoe, the pin, the shoehold down spring and the cup.SST 09718�00010
(c) Using needle�nose pliers, install the anchor side tensionspring to each shoe.
22. INSTALL REAR BRAKE AUTOMATIC ADJUST LEVERLH
(a) Install the automatic adjust lever to the rear brake shoe.
(b) Using needle�nose pliers, install the upper side tensionspring.
F42675
LH: RH:
Front Front
F42838
Expand
32�40�BRAKE REAR DRUM BRAKE (NUMMI/TMMC MADE)
2524Author�: Date�:
2005 COROLLA REPAIR MANUAL (RM1105U)
23. CHECK REAR DRUM BRAKE INSTALLATION(a) Check that each part is installed properly.NOTICE:There should be no oil or grease adhering to the frictionsurfaces of the shoe lining and drum.If they are not installed correctly, reinstall them as shown in theillustration.
24. INSTALL REAR BRAKE DRUM SUB�ASSY(a) Aligning the matchmarks, install the rear brake drum sub�assy.
25. ADJUST REAR DRUM BRAKE SHOE CLEARANCE(a) Temporarily install the hub nuts.
(b) Remove the hole plug, and turn the adjuster and expandthe adjuster until the drum locks.
F42837
Contract
�BRAKE REAR DRUM BRAKE (NUMMI/TMMC MADE)32�41
2525Author�: Date�:
2005 COROLLA REPAIR MANUAL (RM1105U)
(c) Using a screwdriver, back off the adjuster 8 notches.(d) Install the hole plug.
26. FILL RESERVOIR WITH BRAKE FLUID (SEE PAGE 32�5)27. BLEED MASTER CYLINDER (SEE PAGE 32�5)
SST 09023�0010128. BLEED BRAKE LINE (SEE PAGE 32�5)29. CHECK FLUID LEVEL IN RESERVOIR (SEE PAGE 32�5)30. CHECK FOR BRAKE FLUID LEAKAGE31. INSTALL REAR WHEEL
Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf)32. INSPECT PARKING BRAKE LEVER TRAVEL (SEE PAGE 33�2)33. ADJUST PARKING BRAKE LEVER TRAVEL (SEE PAGE 33�2)
3215F�03
F49548
Matchmarks
F47456
Automatic Adjust Lever
Contract
F06408
Brake Drum Gauge
F47457
SST
�BRAKE REAR DRUM BRAKE (TMC MADE)32�43
2527Author�: Date�:
2005 COROLLA REPAIR MANUAL (RM1105U)
OVERHAULHINT:� Use the same procedures for the RH side and LH side.� The procedures listed below are for the LH side.
1. REMOVE REAR WHEEL2. DRAIN BRAKE FLUIDNOTICE:Wash brake fluid off immediately if it adheres to any painted surface.
3. REMOVE REAR BRAKE DRUM SUB�ASSY(a) Put matchmarks on the rear brake drum sub�assy and
the axle hub.(b) Release the parking brake and remove the rear brake
drum sub�assy.HINT:If the brake drum cannot be removed easily, do the followingsteps.
(c) Remove the hole plug and insert a screwdriver throughthe hole in the backing plate, and hold the automatic ad-justing lever away from the adjuster.
(d) Using another screwdriver, contract the brake shoe ad-juster by turning the adjusting bolt.
4. INSPECT BRAKE DRUM INSIDE DIAMETER(a) Using a brake drum gauge or equivalent, measure the in-
side diameter of the drum.Standard inside diameter: 200.0 mm (7.874 in.)Maximum inside diameter: 201.0 mm (7.913 in.)
HINT:If the inside diameter of the brake drum is at the maximum ormore, replace the brake drum sub�assy.
5. SEPARATE PARKING BRAKE SHOE STRUT SET LH(a) Using SST, separate the spring and shoe strut set from
the brake shoes.SST 09703�30011
NOTICE:Be careful not to damage the cylinder dust boot.
F47458
SST
C68552
F47459
SST
F09780
32�44�BRAKE REAR DRUM BRAKE (TMC MADE)
2528Author�: Date�:
2005 COROLLA REPAIR MANUAL (RM1105U)
6. REMOVE FRONT BRAKE SHOE(a) Using SST, remove the cup, shoe hold�down spring and
pin.SST 09718�00010
(b) Remove the front brake shoe and tension spring.
7. REMOVE PARKING BRAKE SHOE STRUT SET LH
8. REMOVE AUTOMATIC ADJUST LEVER LH(a) Remove the tension spring and the automatic adjust le-
ver.
9. REMOVE REAR BRAKE SHOE(a) Using SST, remove the cup, shoe hold�down spring and
pin.SST 09718�00010
(b) Using needle�nose pliers, separate the parking brakecable No.3 and remove the rear brake shoe.
F42689
F42690
Ruler
R01564
F45401
�BRAKE REAR DRUM BRAKE (TMC MADE)32�45
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2005 COROLLA REPAIR MANUAL (RM1105U)
10. REMOVE PARKING BRAKE SHOE LEVER LH(a) Using a screwdriver, remove the C�washer and parking
brake shoe lever sub�assy.
11. INSPECT REAR DRUM BRAKE SHOE LININGTHICKNESS
(a) Using a ruler, measure the thickness of the shoe lining.Standard thickness: 4.4 mm (0.173 in.)Minimum thickness: 1.0 mm (0.039 in.)
If the lining thickness is at the minimum thickness or less, or ifthere is severe or uneven wear, replace the brake shoe.
12. INSPECT BRAKE DRUM AND REAR DRUM BRAKESHOE LINING FOR PROPER CONTACT
(a) Apply chalk to the inside surface of the drum, then grindthe drum on the brake shoe lining to fit.
If the contact between the drum and the shoe lining is improper,repair it using a brake shoe grinder or replace the brake shoeassembly.
13. REMOVE REAR WHEEL BRAKE CYLINDER ASSY(a) Using SST, disconnect the brake line.
SST 09023�00101HINT:Use a container to catch the brake fluid.(b) Remove the bolt and the wheel brake cylinder assy.
14. REMOVE REAR WHEEL CYLINDER CUP KIT(a) Remove the 2 cylinder dust boots from the wheel brake cylinder assy.(b) Remove the 2 pistons and the compression spring.(c) Remove the 2 wheel cylinder cups from each piston.15. INSPECT BRAKE WHEEL CYLINDER(a) Check the cylinder bore and the piston for rust or scoring.If necessary, replace the brake wheel cylinder assy.16. REMOVE REAR DRUM BRAKE BLEEDER PLUG(a) Remove the bleeder plug from the wheel brake cylinder assy.
C57785C57785 F44261Lithium soap base glycol grease
Compression Spring
BootPiston
Cap
F45401
F45407High temperature grease
C62256
32�46�BRAKE REAR DRUM BRAKE (TMC MADE)
2530Author�: Date�:
2005 COROLLA REPAIR MANUAL (RM1105U)
17. TEMPORARILY TIGHTEN REAR DRUM BRAKE BLEEDER PLUG(a) Install the bleeder plug to the wheel brake cylinder assy.
18. INSTALL REAR WHEEL CYLINDER CUP KIT(a) Apply lithium soap base glycol grease to 2 new wheel cyl-
inder cups and 2 pistons.(b) Install the 2 wheel cylinder cups on each piston.(c) Install the compression spring and the 2 pistons to the
wheel brake cylinder.(d) Install the 2 new cylinder dust boots to the wheel brake
cylinder.
19. INSTALL REAR WHEEL BRAKE CYLINDER ASSY(a) Install the wheel brake cylinder assy with the bolt.
Torque: 9.8 N⋅m (100 kgf⋅cm, 87 in⋅lbf)(b) Using SST, connect the brake line.
SST 09023�00101Torque: 15 N⋅m (155 kgf⋅cm, 11 ft⋅lbf)
20. APPLY HIGH TEMPERATURE GREASE(a) Apply high temperature grease to the shoe attached sur-
face of the backing plate.
21. INSTALL PARKING BRAKE SHOE LEVER LH(a) Using needle�nose pliers, install the parking brake shoe
lever sub�assy with a new C�washer.
F45648
F45280
SST
C68552
F45616High temperature grease
Adjusting Bolt
�BRAKE REAR DRUM BRAKE (TMC MADE)32�47
2531Author�: Date�:
2005 COROLLA REPAIR MANUAL (RM1105U)
22. INSTALL REAR BRAKE SHOE(a) Using needle�nose pliers, connect the parking brake
cable No.3 to the parking brake shoe lever sub�assy.
(b) Using SST, install the brake shoe, the pin, the shoe hold�down spring and the shoe hold�down cup.SST 09718�00010
23. INSTALL REAR BRAKE SHOE RETURN SPRING(a) Install the shoe return spring to the brake shoe.
24. INSTALL AUTOMATIC ADJUST LEVER LH(a) Install the automatic adjust lever and the automatic adjust
lever tension spring to the front brake shoe.
25. INSTALL PARKING BRAKE SHOE STRUT SET LH(a) Apply high temperature grease to the adjusting bolt and
assemble.(b) Install the shoe return spring to the strut set.
F40013
Backing Plate
Parking Brake Shoe Strut Set
F45279SST
F45278
SST
32�48�BRAKE REAR DRUM BRAKE (TMC MADE)
2532Author�: Date�:
2005 COROLLA REPAIR MANUAL (RM1105U)
(c) Install the parking brake shoe strut set as shown in the il-lustration.
26. INSTALL FRONT BRAKE SHOE(a) Install the tension spring to the brake shoes.(b) Using SST, install the front brake shoe, the pin, the shoe
hold�down spring and the cup.SST 09718�00010
27. INSTALL PARKING BRAKE SHOE STRUT SET LH(a) Using SST, install the shoe return spring to the brake
shoes.SST 09703�30011
NOTICE:Be careful not to damage the wheel cylinder boot.
F40022
LH: RH:
Front Front
F40023
Expand
Automatic AdjustLever
�BRAKE REAR DRUM BRAKE (TMC MADE)32�49
2533Author�: Date�:
2005 COROLLA REPAIR MANUAL (RM1105U)
28. CHECK REAR DRUM BRAKE INSTALLATION(a) Check that each part is installed properly.NOTICE:There should be no oil or grease adhering to the frictionsurfaces of the shoe lining and drum.If they are not installed correctly, reinstall them as shown in theillustration.
29. INSTALL REAR BRAKE DRUM SUB�ASSY(a) Aligning the matchmarks, install the rear brake drum sub�assy.
30. ADJUST REAR DRUM BRAKE SHOE CLEARANCE(a) Temporarily install the hub nuts.
(b) Remove the hole plug, and turn the adjuster to expandthe shoe until the drum locks.
(c) Rotate the adjuster by 8 notches.(d) Install the hole plug.
31. FILL RESERVOIR WITH BRAKE FLUID (SEE PAGE 32�5)32. BLEED MASTER CYLINDER (SEE PAGE 32�5)
SST 09023�0010133. BLEED BRAKE LINE (SEE PAGE 32�5)34. CHECK FLUID LEVEL IN RESERVOIR (SEE PAGE 32�5)
32�50�BRAKE REAR DRUM BRAKE (TMC MADE)
2534Author�: Date�:
2005 COROLLA REPAIR MANUAL (RM1105U)
35. CHECK FOR BRAKE FLUID LEAKAGE36. INSTALL REAR WHEEL
Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf)37. INSPECT PARKING BRAKE LEVER TRAVEL (SEE PAGE 33�2)38. ADJUST PARKING BRAKE LEVER TRAVEL (SEE PAGE 33�2)