rear brake shoe, wheel cylinder & brake...

REAR BRAKE SHOE, WHEEL CYLINDER & BRAKE DRUM (NUMMI/TMMC MADE) >

COMPONENTS

REAR BRAKE SHOE, WHEEL CYLINDER & BRAKE DRUM (NUMMI/TMMC MADE) >

OVERHAUL

HINT:

Use the same procedures for the RH side and LH side.

The procedures listed below are for the LH side.

Vehicle Reference: BRAKES - MECHANICAL

2005 Toyota Corolla 1.8L Eng CE

Fig 1: Identifying Rear Drum Brake Components - NUMMI/TMMC MADE

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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REMOVE REAR WHEEL 1.

DRAIN BRAKE FLUID

NOTE: Wash brake fluid off immediately if it

adheres to any painted surface.

2.

REMOVE REAR BRAKE DRUM SUB-ASSY

Put matchmarks on the rear brake drum sub-assy and the axle hub.a.

Release the parking brake and remove the rear brake drum sub-assy.

HINT:

If the brake drum cannot be removed easily, do the following steps.

b.

Remove the hole plug and insert a screwdriver through the hole in the backing plate, and holdc.

3.

Fig 1: Putting Matchmarks On Rear Brake Drum Sub-Assy And Axle Hub



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the automatic adjusting lever away from the adjuster.

Using another screwdriver, contract the brake shoe adjuster by turning the adjusting bolt.d.

INSPECT BRAKE DRUM INSIDE DIAMETER

Using a brake drum gauge or equivalent, measure the inside 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 or more, replace the brake drum

sub-assy.

a.

4.

Fig 2: Inserting Screwdriver Through Hole In Backing Plate



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REMOVE REAR BRAKE AUTOMATIC ADJUST LEVER LH

Using needle-nose pliers, remove the upper side tension spring.a.

Remove the rear brake automatic adjust lever LH from the rear brake shoe.b.

5.

Fig 3: Measuring Inside Diameter Of Drum



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REMOVE FRONT BRAKE SHOE

Using needle-nose pliers, remove the anchor side tension spring.a.

6.

Fig 4: Removing Rear Brake Automatic Adjust Lever LH



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Using SST, remove the cup, shoe hold-down spring and pin.

SST 09718-00010

b.

Separate the upper side return spring from the front brake shoe, and remove the front brake

shoe.

c.

Fig 5: Removing Anchor Side Tension Spring



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REMOVE PARKING BRAKE SHOE STRUT SET LH 7.

REMOVE REAR BRAKE SHOE


SST 09718-00010

a.

8.

Fig 6: Removing Cup, Shoe Hold-Down Spring And Pin



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Using needle-nose pliers, separate the parking brake cable No.3 and remove the rear brake

shoe.

b.

Remove the upper side return spring from the rear brake shoe.c.

Fig 7: Removing Cup, Shoe Hold-Down Spring And Pin



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REMOVE REAR BRAKE PARKING BRAKE SHOE LEVER SUB-ASSY

Using a screwdriver, remove the C-washer and parking brake shoe lever sub-assy.a.

9.

Fig 8: Removing Rear Brake Shoe



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INSPECT REAR DRUM BRAKE SHOE LINING THICKNESS

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.)

a.

If the lining thickness is at the minimum thickness or less, or if there is severe, uneven wear, replace the

brake shoe.

10.

Fig 9: Removing C-Washer And Parking Brake Shoe Lever Sub-Assy Using Special Tool



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INSPECT BRAKE DRUM AND REAR DRUM BRAKE SHOE LINING FOR PROPER CONTACT

Apply chalk to the inside surface of the drum, then grind 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 shoe assembly.

a.

11.

Fig 10: Measuring Thickness Of Shoe Lining



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REMOVE REAR WHEEL BRAKE CYLINDER ASSY

Using SST, disconnect the brake line.

SST 09023-00101

HINT:

Use a container to catch the brake fluid.

a.

Remove the bolt and the wheel brake cylinder assy.b.

12.

Fig 11: Applying Chalk To Inside Surface Of Drum



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REMOVE REAR WHEEL CYLINDER CUP KIT

Remove the 2 cylinder dust boots from the wheel brake cylinder.a.

Remove the 2 pistons and compression spring.b.

Remove the 2 wheel cylinder cups from each piston.c.

Remove the bleeder plug cap and bleeder plug from the wheel brake cylinder.d.

13.

INSPECT BRAKE WHEEL CYLINDER

Check the cylinder bore and the piston for rust or scoring.

If necessary, replace the wheel brake cylinder assy.

a.

14.

INSTALL REAR WHEEL CYLINDER CUP KIT

Temporarily tighten the bleeder plug to the wheel brake cylinder assy, and install the bleeder plug

cap.

a.

Apply the lithium soap base glycol grease to 2 new wheel cylinder 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 assy.d.

Install 2 new cylinder dust boots to the wheel brake cylinder assy.e.

15.

Fig 12: Disconnecting Brake Line Using Special Tool



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INSTALL REAR WHEEL BRAKE CYLINDER ASSY

Install the wheel brake cylinder assy with the bolt.

Torque: 10 N.m (102 kgf.cm, 7 ft.lbf)

a.

Using SST, connect the brake tube.

SST 09023-00101


b.

16.

Fig 13: Installing Rear Wheel Cylinder Cup Kit



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APPLY HIGH TEMPERATURE GREASE

Apply high temperature grease to the shoe attached surface of the backing plate.a.

17.

Fig 14: Connecting Brake Tube Using Special Tool



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INSTALL REAR BRAKE PARKING BRAKE SHOE LEVER SUB-ASSY

Using pliers, install the parking brake shoe lever sub-assy with a new C-washer.a.

18.

Fig 15: Applying High Temperature Grease To Shoe Attached Surface Of Backing Plate



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INSTALL REAR BRAKE SHOE

Using needle-nose pliers, connect the parking brake cable No.3 to the parking brake shoe lever

sub-assy.

a.

19.

Fig 16: Installing Parking Brake Shoe Lever Sub-Assy With C-Washer Using Special Tool



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Using SST, install the rear brake shoe, the pin, the shoe hold down spring and the shoe hold

down cup.

SST 09718-00010

b.

Connect the upper side return spring to the rear brake shoe.c.

Fig 17: Connecting Parking Brake Cable No.3 To Parking Brake Shoe Lever Sub-Assy Using

Special Tool



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INSTALL PARKING BRAKE SHOE STRUT SET LH

Apply the high temperature grease to the adjusting bolt.a.

Install the parking brake shoe strut set to the rear brake shoe.b.

20.

INSTALL FRONT BRAKE SHOE

Install the upper side return spring to the front brake shoe.a.

21.

Fig 18: Connecting Upper Side Return Spring To Rear Brake Shoe



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Using SST, install the front brake shoe, the pin, the shoe hold down spring and the cup.

SST 09718-00010

b.

Fig 19: Installing Upper Side Return Spring To Front Brake Shoe



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Using needle-nose pliers, install the anchor side tension spring to each shoe.c.

INSTALL REAR BRAKE AUTOMATIC ADJUST LEVER LH

Install the automatic adjust lever to the rear brake shoe.a.

22.

Fig 20: Installing Front Brake Shoe, Pin, Shoe Hold Down Spring And Cup Using Special Tool



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Using needle-nose pliers, install the upper side tension spring.b.

Fig 21: Installing Automatic Adjust Lever To Rear Brake Shoe



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CHECK REAR DRUM BRAKE INSTALLATION

Check that each part is installed properly.a.

NOTE: There should be no oil or grease

adhering to the friction surfaces of the shoe lining

and drum.

If they are not installed correctly, reinstall them as shown in the illustration.

23.

Fig 22: Installing Upper Side Tension Spring Using Special Tool



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INSTALL REAR BRAKE DRUM SUB-ASSY

Aligning the matchmarks, install the rear brake drum sub-assy.a.

24.

ADJUST REAR DRUM BRAKE SHOE CLEARANCE

Temporarily install the hub nuts.a.

Remove the hole plug, and turn the adjuster and expand the adjuster until the drum locks.b.

25.

Fig 23: Checking Rear Drum Brake Installation



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Using a screwdriver, back off the adjuster 8 notches.c.

Install the hole plug.d.

Fig 24: Removing Hole Plug



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FILL RESERVOIR WITH BRAKE FLUID (see BRAKE FLUID ) 26.

BLEED MASTER CYLINDER (see BRAKE FLUID )

SST 09023-00101

27.

BLEED BRAKE LINE (see BRAKE FLUID ) 28.

CHECK FLUID LEVEL IN RESERVOIR (see BRAKE FLUID ) 29.

CHECK FOR BRAKE FLUID LEAKAGE 30.

INSTALL REAR WHEEL

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

31.

INSPECT PARKING BRAKE LEVER TRAVEL (see ADJUSTMENT ) 32.

ADJUSTMENT PARKING BRAKE LEVER TRAVEL (see ADJUSTMENT ) 33.

REAR BRAKE SHOE, WHEEL CYLINDER & BRAKE DRUM (TMC MADE) > COMPONENTS

Fig 25: Installing Hole Plug Using Special Tool



26 of 52 1/25/2015 6:44 AM

REAR BRAKE SHOE, WHEEL CYLINDER & BRAKE DRUM (TMC MADE) > OVERHAUL

HINT:

Use the same procedures for the RH side and LH side.

The procedures listed below are for the LH side.

REMOVE REAR WHEEL 1.

DRAIN BRAKE FLUID

NOTE: Wash brake fluid off immediately if it

adheres to any painted surface.

2.

Fig 1: Identifying Rear Drum Brake Components - TMC Made



27 of 52 1/25/2015 6:44 AM

REMOVE REAR BRAKE DRUM SUB-ASSY

Put matchmarks on the rear brake drum sub-assy and the axle hub.a.

Release the parking brake and remove the rear brake drum sub-assy.

HINT:

If the brake drum cannot be removed easily, do the following steps.

b.

Remove the hole plug and insert a screwdriver through the hole in the backing plate, and hold

the automatic adjusting lever away from the adjuster.

c.

Using another screwdriver, contract the brake shoe adjuster by turning the adjusting bolt.d.

3.

Fig 1: Putting Matchmarks On Rear Brake Drum Sub-Assy And Axle Hub



28 of 52 1/25/2015 6:44 AM

INSPECT BRAKE DRUM INSIDE DIAMETER

Using a brake drum gauge or equivalent, measure the inside 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 or more, replace the brake drum

sub-assy.

a.

4.

Fig 2: Inserting Screwdriver Through Hole In Backing Plate



29 of 52 1/25/2015 6:44 AM

SEPARATE PARKING BRAKE SHOE STRUT SET LH

Using SST, separate the spring and shoe strut set from the brake shoes.

SST 09703-30011

a.

NOTE: Be careful not to damage the cylinder

dust boot.

5.

Fig 3: Measuring Inside Diameter Of Drum Using Special Tool



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REMOVE FRONT BRAKE SHOE


SST 09718-00010

a.

Remove the front brake shoe and tension spring.b.

6.

Fig 4: Removing Spring And Shoe Strut Set From Brake Shoes Using Special Tool



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REMOVE PARKING BRAKE SHOE STRUT SET LH 7.

REMOVE AUTOMATIC ADJUST LEVER LH

Remove the tension spring and the automatic adjust lever.a.

8.

Fig 5: Removing Front Brake Shoe And Tension Spring



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REMOVE REAR BRAKE SHOE


SST 09718-00010

a.

9.

Fig 6: Removing Tension Spring And Automatic Adjust Lever



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Using needle-nose pliers, separate the parking brake cable No.3 and remove the rear brake

shoe.

b.

Fig 7: Removing Cup, Shoe Hold-Down Spring And Pin Using Special Tool



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REMOVE PARKING BRAKE SHOE LEVER LH

Using a screwdriver, remove the C-washer and parking brake shoe lever sub-assy.a.

10.

Fig 8: Removing Rear Brake Shoe Using Special Tool



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INSPECT REAR DRUM BRAKE SHOE LINING THICKNESS

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.)

a.

If the lining thickness is at the minimum thickness or less, or if there is severe or uneven wear, replace the

brake shoe.

11.

Fig 9: Removing C-Washer And Parking Brake Shoe Lever Sub-Assy Using Special Tool



36 of 52 1/25/2015 6:44 AM

INSPECT BRAKE DRUM AND REAR DRUM BRAKE SHOE LINING FOR PROPER CONTACT

Apply chalk to the inside surface of the drum, then grind the drum on the brake shoe lining to fit.a.

If the contact between the drum and the shoe lining is improper, repair it using a brake shoe grinder or

replace the brake shoe assembly.

12.

Fig 10: Measuring Thickness Of Shoe Lining Using Special Tool



37 of 52 1/25/2015 6:44 AM

REMOVE REAR WHEEL BRAKE CYLINDER ASSY

Using SST, disconnect the brake line.

SST 09023-00101

HINT:

Use a container to catch the brake fluid.

a.

Remove the bolt and the wheel brake cylinder assy.b.

13.

Fig 11: Applying Chalk To Inside Surface Of Drum



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REMOVE REAR WHEEL CYLINDER CUP KIT

Remove the 2 cylinder dust boots from the wheel brake cylinder assy.a.

Remove the 2 pistons and the compression spring.b.

Remove the 2 wheel cylinder cups from each piston.c.

14.

INSPECT BRAKE WHEEL CYLINDER

Check the cylinder bore and the piston for rust or scoring. If necessary, replace the brake wheel

cylinder assy.

a.

15.

REMOVE REAR DRUM BRAKE BLEEDER PLUG

Remove the bleeder plug from the wheel brake cylinder assy.a.

16.

TEMPORARILY TIGHTEN REAR DRUM BRAKE BLEEDER PLUG

Install the bleeder plug to the wheel brake cylinder assy.a.

17.

INSTALL REAR WHEEL CYLINDER CUP KIT

Apply lithium soap base glycol grease to 2 new wheel cylinder cups and 2 pistons.a.

Install the 2 wheel cylinder cups on each piston.b.

Install the compression spring and the 2 pistons to the wheel brake cylinder.c.

Install the 2 new cylinder dust boots to the wheel brake cylinder.d.

18.

Fig 12: Removing Bolt And Wheel Brake Cylinder Assy



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INSTALL REAR WHEEL BRAKE CYLINDER ASSY

Install the wheel brake cylinder assy with the bolt.

Torque: 9.8 N.m (100 kgf.cm, 87 in.lbf)

a.

Using SST, connect the brake line.

SST 09023-00101


b.

19.

Fig 13: Installing Cylinder Dust Boots To Wheel Brake Cylinder



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APPLY HIGH TEMPERATURE GREASE

Apply high temperature grease to the shoe attached surface of the backing plate.a.

20.

Fig 14: Connecting Brake Line Using Special Tool



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INSTALL PARKING BRAKE SHOE LEVER LH

Using needle-nose pliers, install the parking brake shoe lever sub-assy with a new C-washer.a.

21.

Fig 15: Applying High Temperature Grease To Shoe Attached Surface Of Backing Plate



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INSTALL REAR BRAKE SHOE

Using needle-nose pliers, connect the parking brake cable No.3 to the parking brake shoe lever

sub-assy.

a.

22.

Fig 16: Installing Parking Brake Shoe Lever Sub-Assy With C-Washer Using Special Tool



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Using SST, install the brake shoe, the pin, the shoe hold-down spring and the shoe hold-down

cup.

SST 09718-00010

b.

Fig 17: Connecting Parking Brake Cable No.3 To Parking Brake Shoe Lever Sub-Assy Using

Special Tool



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INSTALL REAR BRAKE SHOE RETURN SPRING

Install the shoe return spring to the brake shoe.a.

23.

INSTALL AUTOMATIC ADJUST LEVER LH

Install the automatic adjust lever and the automatic adjust lever tension spring to the front brake

shoe.

a.

24.

Fig 18: Installing Brake Shoe, Pin, Shoe Hold-Down Spring And Shoe Hold-Down Cup Using Special

Tool



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Apply high temperature grease to the adjusting bolt and assemble.a.

Install the shoe return spring to the strut set.b.

25.

Fig 19: Installing Automatic Adjust Lever And Automatic Adjust Lever Tension Spring To Front Brake

Shoe



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Install the parking brake shoe strut set as shown in the illustration.c.

Fig 20: Installing Shoe Return Spring To Strut Set



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INSTALL FRONT BRAKE SHOE

Install the tension spring to the brake shoes.a.

Using SST, install the front brake shoe, the pin, the shoe hold-down spring and the cup.

SST 09718-00010

b.

26.

Fig 21: Installing Parking Brake Shoe Strut Set



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Using SST, install the shoe return spring to the brake shoes.

SST 09703-30011

a.

NOTE: Be careful not to damage the wheel

cylinder boot.

27.

Fig 22: Installing Front Brake Shoe, Pin, Shoe Hold-Down Spring And Cup Using Special Tool



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CHECK REAR DRUM BRAKE INSTALLATION

Check that each part is installed properly.a.

NOTE: There should be no oil or grease

adhering to the friction surfaces of the shoe lining

and drum.

If they are not installed correctly, reinstall them as shown in the illustration.

28.

Fig 23: Installing Shoe Return Spring To Brake Shoes Using Special Tool



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INSTALL REAR BRAKE DRUM SUB-ASSY

Aligning the matchmarks, install the rear brake drum sub-assy.a.

29.

ADJUST REAR DRUM BRAKE SHOE CLEARANCE

Temporarily install the hub nuts.a.

Remove the hole plug, and turn the adjuster to expand the shoe until the drum locks.b.

Rotate the adjuster by 8 notches.c.

Install the hole plug.d.

30.

Fig 24: Checking Rear Drum Brake Installation



51 of 52 1/25/2015 6:44 AM

FILL RESERVOIR WITH BRAKE FLUID (see BRAKE FLUID ) 31.

BLEED MASTER CYLINDER (see BRAKE FLUID )

SST 09023-00101

32.

BLEED BRAKE LINE (see BRAKE FLUID ) 33.

CHECK FLUID LEVEL IN RESERVOIR (see BRAKE FLUID ) 34.

CHECK FOR BRAKE FLUID LEAKAGE 35.

INSTALL REAR WHEEL

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

36.

INSPECT PARKING BRAKE LEVER TRAVEL (see ADJUSTMENT ) 37.

ADJUST PARKING BRAKE LEVER TRAVEL (SEE ADJUSTMENT ) 38.

Fig 25: Adjusting Rear Drum Brake Shoe Clearance



52 of 52 1/25/2015 6:44 AM

rear brake shoe, wheel cylinder & brake...

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