COMPONENTS

EJSE210G
EJSE210H
REMOVAL 4. Remove the caliper mounting bolts (A) from the
1. Remove the wheel and tire. knuckle then remove the caliper mounting bracket.
2. Remove the brake hose mounting bolt (A) from the
caliper then disconnect the brake hose (B).

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CAUTION
• Do not spill brake fluid on the vehicle; it may
damage the paint;if brake fluid does contact
the paint, wash it off immediately with water.
• To prevent spills, plug the hose inlets with
rags or shop towels.
3. Remove the guide rod bolt (A) and the caliper up out
of the way. Check the hoses and pin boots for
damage and deterioration.

KJSE210M
REPLACEMENT 4. Remove the pad shims (A), pad (B) and pad retainers
1. Loosen the front wheel nuts slightly. Raise the front (C).
of the vehicle, and make sure it is securely CAUTION
supported. Remove the front wheels. Do not depress the brake pedal while
2. Before removing the brake pad, visually inspect the disassembling the pads.
pad thickness.

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3. Remove guide rod bolt (A) and the caliper up out of
the way. Check the hoses and pin boots for damage
and deterioration.
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5. Using vernier calipers, measure the thickness of each
brake pad lining. The measurement does not include
pad backing plate (A) thickness.
Brake pad thickness:
Standard: 11mm (0.43 in.)
Service limit: 2mm (0.079 in.)

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EJKE400C

6. If the brake pad thickness is less than service limit,

replace the front pads as a set.
7. Clean the caliper thoroughly; remove any rust, and
check for grooves and cracks.
8. Check the brake disc for damage and cracks.
9. Install the pad retainers (A). 11.Install the brake pads (A) and pad shims (B)
correctly. Install the pad with the wear indicator on
the inside.
If you are reusing the pads, always reinstall the brake
pads in their original positions to prevent a
momentary loss of braking efficiency.
12.Push in the piston so that the caliper will fit over the
pads. Make sure that the piston boot is in position to
prevent damaging it when pivoting the caliper down.
13.Pivot the caliper down into position. Being careful not
to damage the pin boot, install the guide rod bolt (A)
and torque it to proper specification.

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10.Check the foreign material at the pad shims (B) and

the back of the pads (A).
Contaminated brake discs or pads reduce stopping
ability. Keep grease off the discs and pads.

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NOTICE
Insert the piston in the cylinder using the special tool
(09581-11000).

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14.Depress the brake pedal several times to make sure 3. Remove the piston seal from the caliper by using a
the brakes work, then test-drive. finger.
NOTICE CAUTION
Engagement of the brake may require a greater Take care not to damage the piston wall surface.
pedal stroke immediately after the brake pads have
been replaced as a set.Several applications of the
brake will restore the normal pedal stroke.
15.After installation, check for leaks at hose and line
joints or connections, and retighten if necessary.

DISASSEMBLY
1. Remove the piston boot.

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2. Remove the piston using compressed air.

NOTICE
1. Do not put your fingers in front of the piston
when using compressed air.
2. Be careful not to splatter the brake fluid.

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INSPECTION
Runout
1. Loosen the front wheel nuts slightly, then raise the
vehicle and make sure it is securely supported.
Remove the front wheels.
2. Remove the brake pads.
3. Inspect the disc surface for damage and cracks.
Clean the disc thoroughly and remove all rust.
4. Use wheel nuts and suitable flat washers to hold the
disc securely against the hub, then mount a dial
indicator as shown, and measure the runout at 10
mm (0.4 in.) from the outer edge of the disc.
Brake disc runout:
Service limit: 0.10 mm (0.004 in.)
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5. If the disc is beyond the service limit, refinish the
brake disc with an on-car brake lathe.
Max. Refinish limit: 24 mm (0.945 in.)
NOTICE
• If the brake disc is beyond the service limit for
refinishing, replace it.
• A new disc should be refinished if its runout is
greater than 0.10 mm (0.004 in.).
Thickness and parallelism
1. Loosen the front wheel nuts slightly, then raise the
vehicle and make sure it is securely supported.
Remove the front wheels.
2. Remove the brake pads.
3. Using measure disc thickness at eight points,
approximately 45° apart and 10 mm (0.4 in.) in from
the outer edge of the disc. Replace the brake disc of
the smallest measurement is less than the max.
refinishing limit.
Brake disc thickness:
Standard: 26mm (1.024 in.)
Max. Refinishing limit: 24 mm (0.945 in.)
Brake disc parallelism: Max. 0.015 mm (0.0006 in.)
NOTICE
This is the maximum allowable difference between
the thickness measurements.
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4. If the disc is beyond the service limit for parallelism,
refinish the brake disc with an on-car brake lathe.
NOTICE
If the brake disc is beyond the service limit for
refinishing, replace it.
REASSEMBLY
1. Clean all components except the pads and shims
with isopropyl alcohol.
2. Apply rubber grease on the piston seal and install the
piston seal in the cylinder.
3. Assemble the piston and piston boots according to
the following procedure.
1) Apply rubber grease to the caliper bore, the
outside surface of the piston and the piston boot.
2) Install the piston boot (B) on the piston(A) as
illustrated.
3) Insert the piston boot in the inner groove of the
caliper(C) and push the piston into the caliper.

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4. Assemble the sliding parts according to the following

procedure.
1) Apply rubber grease to the outside surface of the
guide rod pin, bore of the caliper, and pin boot.
2) Insert the boot into the groove of the caliper.
Rear Drum Brake
COMPONENTS

EJSE130A
REMOVAL INSTALLATION
1. Raise the rear of the vehicle, and make sure it is 1. Apply specified sealant (A) on wheel cylinder and
securely supported. backing plate contact surface.
2. Release the parking brake, and remove the rear Specified sealant:
brake drum. 3M Sealant Part No. 8634 or equivalent
3. Remove the overload spring and shoe return spring
from the anchor pin.

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2. Install the return spring on the anchor pin.

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3. Apply specified sealant (A) on shoe hold down pin at
4. Remove the shoe hold down pin by pushing the shoe backing plate assembly install surface.
hold down washer and turning them.
Specified sealant:
3M Sealant Part No. 8634 or equivalent

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5. Remove the self-adjuster spring and self-adjuster

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lever then separate the brake shoes.
6. Disconnect the parking brake cable from the parking
brake lever.
4. Apply specified grease to backing plate as illustrated. INSPECTION
1) Shoe and lever, and shoe and lining assembly CAUTION
and backing plate contact parts. Frequent inhalation of brake pad dust, regardless of
2) Anchor plate and wheel cylinder piston edges. material composition, could be hazardous to your
Specified grease: Brake grease SAE J310, NLGI No.1 health.
• Avoid breathing dust particles.
• Never use an air hose or brush to clean brake
assemblies.
NOTICE
• Contaminated brake linings or drums reduce
stopping ability.
• Block the front wheels before jacking up the rear of
the vehicle.
1. Raise the rear of the vehicle, and make sure it is
securely supported.
2. Release the parking brake, and remove the rear
brake drum.
3. Check the wheel cylinder for leakage.
4. Check the brake linings for cracking, glazing, wear,
KJSE200M and contamination.
5. Apply specified grease (A) to adjusting screw 5. Measure the brake lining thickness.
assembly as illustrated. Measurement does not include brake shoe thickness.
Specified grease: Brake grease SAE J310, NLGI No.1
Brake lining thickness:
Standard: 4.5 mm (0.177 in.)
Service limit: 1.0 mm (0.039 in.)

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6. Install so that adjusting screw identifying groove

faces to shoe and lining assembly and outside.
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6. If the brake lining thickness is less than the service

limit, replace the brake shoes as a set.
7. Check the bearings in the hub unit for smooth
operation. If it requires servicing, replace it.
8. Measure the inside diameter of the brake drum with DISASSEMBLY
inside vernier calipers.
CAUTION
Drum inside diameter: When removing the piston cup, be sure not to
Standard: 260 mm (10.24 in.) damage the piston.
Service limit: 262 mm (10.315 in.)

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EJKE800B

9. If the inside diameter of the brake drum is more than

the service limit, replace the brake drum.
10.Check the brake drum for scoring, grooves, and
cracks.

EJSE199G
REASSEMBLY
Piston cup and piston
1. Clean piston with trichloroethylene, alcohol
specified brake fluid.
Specified brake fluid: SAE J1703 (DOT 3 or DOT 4)
2. Apply specified brake fluid on piston cup and outer
surface of special tool.
3. Set the special tool on piston (A). Insert piston cup
(B) with lip upward in special tool.
4. Gently ease piston cup into piston groove.
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Piston assembly
1. Clean inner wheel cylinder body with specified brake
or fluid.
Specified brake fluid: SAE J1703 (DOT 3 or DOT 4)
2. Apply specified brake fluid (A) on inner wheel cylinder
body and exterior piston cup. Install piston assembly.
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3. Fill piston edge with specified grease (A).
Specified grease: Repair kit grease (orange)
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