Toyota Highlander Service Manual: Rear brake

Toyota Highlander Service Manual / Brake / Rear brake

COMPONENTS

COMPONENTS

OVERHAUL

HINT:

Use the same procedures for the RH side and LH side.
The procedures listed below are for the LH side.

1. REMOVE REAR WHEEL

2. DRAIN BRAKE FLUID

NOTICE: Wash brake fluid off immediately if it adheres to any painted surface.

3. DISCONNECT REAR LH FLEXIBLE HOSE

(a) Remove the union bolt and gasket from the rear disc brake cylinder, then disconnect the flexible hose from the rear disc brake cylinder.

4. REMOVE REAR DISC BRAKE CYLINDER SLIDE PIN

REMOVE REAR DISC BRAKE CYLINDER SLIDE PIN

(a) Remove the rear disc brake cylinder slide pin and rear disc brake cylinder slide pin No.2.

5. REMOVE DISC BRAKE CYLINDER ASSY REAR LH

REMOVE DISC BRAKE CYLINDER ASSY REAR LH

(a) Remove the disc brake cylinder assy rear LH.

6. REMOVE DISC BRAKE PAD KIT REAR (PAD ONLY)

(a) Remove the 2 brake pads with the anti squeal shim.

7. REMOVE ANTI SQUEAL SHIM KIT REAR

(a) Remove the 4 anti squeal shims from each pad.

(b) Using a screwdriver, remove the 2 pad wear indicators from each pad.

8. REMOVE REAR DISC BRAKE PAD SUPPORT PLATE

(a) Remove the rear disc brake pad support plate (No.1) and the rear disc brake pad support plate (No.2) from the rear disc brake cylinder mounting LH.

9. REMOVE REAR DISC BRAKE BUSH DUST BOOT

REMOVE REAR DISC BRAKE BUSH DUST BOOT

(a) Remove the 2 rear disc brake bush dust boots from the rear disc brake cylinder mounting LH.

10. REMOVE REAR DISC BRAKE CYLINDER MOUNTING LH

REMOVE REAR DISC BRAKE CYLINDER MOUNTING LH

(a) Remove the 2 bolts and the rear disc brake cylinder mounting LH.

11. REMOVE REAR DISC BRAKE CYLINDER SLIDE BUSH

REMOVE REAR DISC BRAKE CYLINDER SLIDE BUSH

(a) Using a screwdriver, remove the rear disc brake cylinder slide bush from the rear disc brake cylinder slide pin No.2.

NOTICE: Do not damage the front disc brake cylinder slide pin No.2.

12. REMOVE CYLINDER BOOT

(a) Using a screwdriver, remove the cylinder boot.

NOTICE: Do not damage the inner cylinder and cylinder groove.

13. REMOVE REAR DISC BRAKE PISTON

REMOVE REAR DISC BRAKE PISTON

(a) Place a shop rag between the rear disc brake piston and the disc brake cylinder assy rear LH.

(b) Use compressed air to remove the rear disc brake piston from the disc brake cylinder assy rear LH.

CAUTION: Do not place your fingers in front of the brake piston when using compressed air.

NOTICE: Do not spatter the brake fluid.

14. REMOVE PISTON SEAL

REMOVE PISTON SEAL

(a) Using a screwdriver, remove the piston seal from the disc brake cylinder assy rear LH.

NOTICE: Do not damage the inner cylinder and the cylinder groove.

15. REMOVE REAR DISC BRAKE BLEEDER PLUG CAP

(a) Remove the rear disc brake bleeder plug cap from the rear disc brake bleeder plug.

16. REMOVE REAR DISC BRAKE BLEEDER PLUG

(a) Remove the rear disc brake bleeder plug from the disc brake cylinder assy rear LH.

17. INSPECT BRAKE CYLINDER AND PISTON

(a) Inspect the cylinder bore and the brake piston for rust or scoring.

If necessary, replace the brake cylinder and piston.

18. INSPECT PAD LINING THICKNESS

INSPECT PAD LINING THICKNESS

(a) Using a ruler, measure the pad lining thickness.

Standard thickness: 10.0 mm (0.394 in.) Minimum thickness: 1.0 mm (0.039 in.)

If the pad lining thickness is equal to the minimum thickness or less, replace the brake pad.

19. INSPECT REAR DISC BRAKE PAD SUPPORT PLATE

(a) Inspect the rear disc brake pad support plate (No.1) and the rear disc brake pad support plate (No.2).

Make sure that both have sufficient rebound, have no deformation, cracks or wear, and that all rust and dirt are cleaned off.

If necessary, replace the rear disc brake pad support plate.

20. INSPECT DISC THICKNESS

INSPECT DISC THICKNESS

(a) Using a micrometer, measure the disc thickness.

Standard thickness: 10.0 mm (0.394 in.) Minimum thickness: 8.5 mm (0.335 in.)

If the disc thickness is less than the minimum, replace the disc.

21. REMOVE REAR DISC

REMOVE REAR DISC

(a) Put matchmarks on the rear disc and the axle hub.

REMOVE REAR DISC

(b) Release the parking brake, and remove the rear disc.

HINT: If the disc cannot be removed easily, turn the shoe adjuster until the wheel turns freely.

22. REMOVE PARKING BRAKE SHOE ADJUSTING HOLE PLUG

(a) Remove the parking brake shoe adjusting hole plug from the rear disc.

23. INSTALL PARKING BRAKE SHOE ADJUSTING HOLE PLUG

(a) Install the parking brake shoe adjusting hole plug to the rear disc.

24. INSTALL REAR DISC

(a) Aligning the matchmarks, install the rear disc.

HINT: When replacing the rear disc with a new one, select the installation position where the rear disc has the minimum runout.

25. INSPECT DISC RUNOUT

INSPECT DISC RUNOUT

(a) Temporarily fasten the rear disc with hub nuts.

Torque: 103 NVm (1,050 kgfVcm, 76 ftVlbf) (b) Using a dial indicator, measure the disc runout 10 mm (0.39 in.) away from the outer edge of the rear disc.

Maximum disc runout: 0.15 mm (0.0059 in.) (c) If the runout exceeds the maximum value, change the installation positions of the disc and axle so that the runout will become minimal. If the runout exceeds the maximum even when the installation positions are changed, check the bearing play in the axial direction and the axle hub runout (see page 30-3 ). If the bearing play and the axle hub runout are normal and if the disc thickness is not within the specified range, shave the disc. If the disc thickness is less than the minimum, replace the disc.

26. ADJUST PARKING BRAKE SHOE CLEARANCE (SEE PAGE 33-19 )

27. TEMPORARILY TIGHTEN REAR DISC BRAKE BLEEDER PLUG

(a) Temporarily tighten the rear disc brake bleeder plug to the disc brake cylinder assy rear LH.

28. INSTALL REAR DISC BRAKE BLEEDER PLUG CAP

(a) Install the rear disc brake bleeder plug cap to the rear disc brake bleeder plug.

29. INSTALL PISTON SEAL

INSTALL PISTON SEAL

(a) Apply lithium soap base glycol grease to a new piston seal.

(b) Install the piston seal to the disc brake cylinder assy rear LH.

30. INSTALL REAR DISC BRAKE PISTON

(a) Apply lithium soap base glycol grease to the rear disc brake piston and a new cylinder boot.

(b) Install the cylinder boot to the rear disc brake piston.

NOTICE: Do not install the piston forcibly in the disc brake cylinder.

31. INSTALL CYLINDER BOOT

INSTALL CYLINDER BOOT

(a) Install the cylinder boot to the disc brake cylinder assy rear LH.

NOTICE:

Install the boot securely onto the grooves of the cylinder and the piston.
Do not damage the cylinder boot.

32. INSTALL REAR DISC BRAKE CYLINDER SLIDE BUSH

INSTALL REAR DISC BRAKE CYLINDER SLIDE BUSH

(a) Apply lithium soap base glycol grease to a new rear disc brake cylinder slide bush.

(b) Install the rear disc brake cylinder slide bush to the rear disc brake cylinder slide pin No.2.

33. INSTALL REAR DISC BRAKE CYLINDER MOUNTING LH

INSTALL REAR DISC BRAKE CYLINDER MOUNTING LH

(a) Install the rear disc brake cylinder mounting LH with the 2 bolts.

Torque: 78 NVm (800 kgfVcm, 58 ftVlbf)

34. INSTALL REAR DISC BRAKE BUSH DUST BOOT

INSTALL REAR DISC BRAKE BUSH DUST BOOT

(a) Apply lithium soap base glycol grease to the seal surface of 2 new rear disc brake bush dust boots.

(b) Install the 2 rear disc brake bush dust boots to the rear disc brake cylinder mounting LH.

35. INSTALL REAR DISC BRAKE PAD SUPPORT PLATE

(a) Install the rear disc brake pad support plate (No.1) and the rear disc brake pad support plate (No.2) to the rear disc brake cylinder mounting LH.

36. INSTALL ANTI SQUEAL SHIM KIT REAR

INSTALL ANTI SQUEAL SHIM KIT REAR

(a) Apply disc brake grease to the inside of the anti squeal shims and install them and the pad wear indicators to each of the 2 brake pads.

NOTICE:

When replacing worn pads, the anti squeal shims must be replaced together with the pads.
Install the pad wear indicator and anti squeal shims in the correct positions and directions.

37. INSTALL DISC BRAKE PAD KIT REAR (PAD ONLY)

(a) Install the 2 brake pads with anti squeal shims to the rear disc brake cylinder mounting LH.

NOTICE: There should be no oil or grease on the friction surface of the pads and the disc.

38. INSTALL DISC BRAKE CYLINDER ASSY REAR LH

INSTALL DISC BRAKE CYLINDER ASSY REAR LH

(a) Install the disc brake cylinder assy rear LH.

39. INSTALL REAR DISC BRAKE CYLINDER SLIDE PIN

INSTALL REAR DISC BRAKE CYLINDER SLIDE PIN

(a) Apply lithium soap base glycol grease to the sliding part and the seal surface of the 2 slide pins.

(b) Install the rear disc brake cylinder slide pin.

INSTALL REAR DISC BRAKE CYLINDER SLIDE PIN

(d) Fully tighten the rear disc brake cylinder slide pin and the rear disc brake cylinder slide pin No.2.

Torque: 43 NVm (440 kgfVcm, 32 ftVlbf)

40. CONNECT REAR LH FLEXIBLE HOSE

(a) Connect the flexible hose with the union bolt and a new gasket.

Torque: 29 NVm (300 kgfVcm, 21 ftVlbf)

41. FILL RESERVOIR WITH BRAKE FLUID (SEE PAGE 32-4 )

42. BLEED MASTER CYLINDER (SEE PAGE 32-4 )

SST 09023-00101

43. BLEED BRAKE LINE (SEE PAGE 32-4 )

44. BLEED BRAKE ACTUATOR ASSY (SEE PAGE 32-4 )

45. CHECK BRAKE FLUID LEAKAGE

46. CHECK FLUID LEVEL IN RESERVOIR (SEE PAGE 32-4 )

47. INSTALL REAR WHEEL

Torque: 103 NVm (1,050 kgfVcm, 76 ftVlbf)

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