Brake

Parking brake

Parking brake system

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PB-2
Symptom table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PB-3
Parking brake lever ASSY
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PB-4
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PB-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PB-6
Parking brake cable ASSY
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PB-7
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PB-9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PB-12
Parking brake ASSY

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Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PB-13
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PB-16
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PB-20
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PB-20
Parking brake switch ASSY
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PB-26
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PB-26
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PB-26
Unit inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PB-27

PB
 PB–2 Parking brake － Parking brake system

Parking brake system

Parking brake
Brake

Adjustment
1. Parking brake lever stroke check
(1) Strongly pull the parking brake lever once.
(2) Release the parking brake lever.
(3) While slowly pulling the parking brake lever, count the number of notches.
Standard value: 7 - 8 notches [Operation force of 200 N{20 kgf/45.0 lbf}]
NOTE:
If it is not within the specified value, adjust the parking brake lever stroke.
2. Adjustment of parking brake
(1) Remove the console cover. (Refer to IT - 37)
(2) Release the parking brake.

(3) Loosen the adjusting nut.

Captions in illustration
*1 Adjusting nut

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*1

(4) Remove the rear tire.

(5) Temporarily tighten the rear wheel nut.
(6) Remove the service hole plug of the rear disc. Turn the rear disc until the service hole is aligned to the adjusting screw.
(7) Using a flat tip screwdriver, turn the adjusting screw in the extension direction until the parking brake shoe is in close con-
tact with the disc.

Captions in illustration
*a Extend *b Contract

(8) Turn the adjusting screw in the retract direction until the rear disc rotates lightly.

PB NOTE:
Standard number of notches to return: 10
(9) Check for brake drag.
(10) Install the service hole plug to the rear disc.
(11) After operating the parking brake lever 3 to 4 times, turn the adjusting nut until the lever stroke is at the specified value.
 Parking brake － Parking brake system
PB–3

Standard value: 7 - 8 notches [Operation force of 200 N{20 kgf/45.0 lbf}]

(12) Tighten the adjusting nut.
(13) After operating the parking brake lever 3 to 4 times, make sure that the lever stroke is within the specified value.
Standard value: 7 - 8 notches [Operation force of 200 N{20 kgf/45.0 lbf}]
(14) Check for brake drag.
(15) Remove the rear wheel nut.
(16) Install the rear tires.
Standard value:T=120N·m {1224kgf·cm} {88.5 ft·lbf}
(17) Install the console cover. (Refer to IT - 38)
3. Brake warning light check
(1) Check that the brake warning light illuminates when the parking brake lever is operated.
Criteria: Make sure that the brake warning light illuminates without fail when the parking brake lever is pulled to the first
notch.

Symptom table
Determine the problem by referring to the table below. Check each part in order, and replace the applicable parts if necessary.
Symptoms Inspection items Reference pages
Parking brake lever stroke (improper adjustment) PB - 2
Parking brake cable front (sticking) PB - 9

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Parking brake cable rear (sticking) PB - 9
Brake drag
Parking brake shoe clearance (improper adjustment) PB - 24
Parking brake shoe (crack or deformation) PB - 16
Tension spring (faulty) PB - 16

PB
 PB–4 Parking brake － Parking brake lever ASSY

Parking brake lever ASSY

Parking brake
Brake

Exploded view

18 {184,13.8}

x3

Parking brak lever ASSY

Parking brak switch ASSY

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1.5 {15,1.1}

Parking brake cable ASSY NO.1

N*m {kgf*cm,ft*lbf} : Tightening torque

PB Non-reusable parts

PB-10002
 Parking brake － Parking brake lever ASSY
PB–5

Removal
1. Removal of console box ASSY (Refer to IT - 37)
2. Removal of parking brake cable ASSY No.1
(1) Release the parking brake.

(2) Remove the adjusting nut.

(3) Disconnect the parking brake cable ASSY No.2 and No.3 from the
parking brake cable ASSY No.1.

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(4) Remove the parking brake cable ASSY No.1 from the parking brake lever.
3. Removal of parking brake lever ASSY
(1) Disconnect the connector for the parking brake switch ASSY.

(2) Remove 3 bolts and then the parking brake lever ASSY.

4. Removal of parking brake switch ASSY

(1) Remove the screw and then the parking brake switch ASSY.

PB
 PB–6 Parking brake － Parking brake lever ASSY

Installation
1. Installation of parking brake switch ASSY
(1) Install the parking brake switch ASSY with a screw.
Standard value:T=1.5N·m {15kgf·cm} {1.1 ft·lbf}
2. Installation of parking lever ASSY
(1) Install the parking brake lever ASSY with 3 bolts.
Standard value:T=18N·m {184kgf·cm} {13.3ft·lbf}
(2) Connect the connector for the parking brake switch ASSY.
3. Installation of parking brake cable ASSY No.1
(1) Attach the parking brake cable ASSY No.1 to the parking brake lever and then secure it with an adjusting nut temporarily.
(2) Connect the parking brake cable No.2 and No.3 to the parking brake cable ASSY No.1.
4. Parking brake lever stroke check (Refer to PB - 2)
5. Adjustment of parking brake lever stroke (Refer to PB - 2)
6. Installation of console box ASSY (Refer to IT - 38)

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PB
 Parking brake － Parking brake cable ASSY
PB–7

Parking brake cable ASSY

Parking brake
Brake

Exploded view

Fuel tank protector Fuel tank protector

Small type Large type Fuel tank protector NO.1

Fuel tank protector Fuel tank protector

NO.1 NO.2

x2 x2
9.0 {92,6.6} x2

9.0 {92,6.6} x2
x2
9.0 {92,6.6}

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N*m {kgf*cm,ft*lbf} : Tightening torque

Non-reusable parts
RS-10139

PB
 PB–8 Parking brake － Parking brake cable ASSY

Exhaust tail pipe ASSY

x2

Gasket
Cushion rubber

x2

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48 {490, 35.4}

Gasket
Exhaust pipe ASSY CTR

x2
x2

x2

18 {184, 13.3}

N*m {kgf*cm, ft*lbf} : Tightening torque

Non-reusable part
PB-10004

PB
 Parking brake － Parking brake cable ASSY
PB–9

Parking brake cable ASSY No. 2

Clamp

18 {184,13.3}

x2
18 {184,13.3} Parking brake cable ASSY No. 3

x2
Clamp

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Clamp (H/B)
x4

18 {184,13.3}

x2 x4
18 {184,13.3}
18 {184,13.3}

Casing lower bracket

Parking brake cable ASSY No. 1

N•m {kgf•cm, ft•lbf} : Tightening torque

PB-00412

Removal PB
1. Removal of console box ASSY (Refer to IT - 33)
2. Removal of parking brake cable ASSY No.1 (Refer to PB - 5)
3. Disconnection of parking brake ASSY (Refer to PB - 16)
 PB–10 Parking brake － Parking brake cable ASSY

4. Removal of clamp (H/B)

(1) Remove 2 nuts and then the clamp (H/B).

5. Removal of casing lower bracket

(1) Remove 2 bolts, and then remove the casing lower bracket.

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6. Removal of fuel tank protector (Refer to FU - 69)
7. Removal of exhaust pipe ASSY CTR
(1) Remove the two nuts, two bolts and two compression springs to
remove the exhaust pipe ASSY CTR.

(2) Remove the two nuts and two bolts to remove the exhaust tail pipe
ASSY.

PB
 Parking brake － Parking brake cable ASSY
PB–11

(3) Remove the cushion rubber, and remove the exhaust pipe ASSY
CTR.
(4) Remove the gasket.

8. Removal of propeller shaft center bearing ASSY (Refer to DP - 14)

9. Removal of parking brake cable ASSY No.3
(1) Remove 4 bolts and then disconnect the parking brake cable ASSY No.3 from the body.

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PB
PB-00420
 PB–12 Parking brake － Parking brake cable ASSY

Captions in illustration

Bolt Front of vehicle

(2) Remove the clamp, and then remove the parking brake cable
ASSY No. 3.

10. Removal of parking brake cable ASSY No.2

NOTE:
Perform the same procedures for the parking brake cable ASSY No.3.

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Installation
1. Installation of parking brake cable ASSY No.3
(1) Push the parking brake cable ASSY No.3 into the backing plate, and then install it with the clamp.
(2) Install the parking brake cable ASSY No.3 to the body with 4 bolts.
Standard value:T=18N·m {184kgf·cm} {13.3ft·lbf}
2. Installation of parking brake cable ASSY No.2
NOTE:
Perform the same procedures for the parking brake cable ASSY No.3.
3. Installation of propeller shaft center bearing ASSY (Refer to DP - 16)
4. Installation of exhaust pipe ASSY CTR
(1) Install the exhaust pipe ASSY CTR with the cushion rubber.
(2) With 2 bolts and 2 new nuts, install the exhaust pipe ASSY CTR to the exhaust tail pipe ASSY via a new gasket.
Standard value:T=48N·m {490kgf·cm} {35.4ft·lbf}
(3) With 2 bolts, 2 nuts, and 2 compression springs, install the exhaust pipe ASSY CTR to the exhaust pipe ASSY FR via a
new gasket.
Standard value:T=18N·m {184kgf·cm} {13.3ft·lbf}
5. Installation of fuel tank protector (Refer to FU - 72)
6. Installation of casing lower bracket
(1) Install the casing lower bracket to the body with 2 bolts.
Standard value:T=18N·m {184kgf·cm} {13.3ft·lbf}
7. Installation of clamp (H/B)
(1) Install the clamp (H/B) to the casing lower bracket to the body with 2 nuts.
Standard value:T=18N·m {184kgf·cm} {13.3ft·lbf}
8. Installation of parking brake cable ASSY No.1 (Refer to PB - 6)

PB
 Parking brake － Parking brake ASSY
PB–13

Parking brake ASSY

Parking brake
Brake

Exploded view
Normal type

Rear disc brake caliper ASSY LH

*1
66 {673,48.7}

*2
110{112,81.1}

x2

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N*m {kgf*cm,ft*lbf} : Tightening torque
*1: Width across flat 14 mm {0.55 in}

Non-reusable parts *2: Width across flat 17 mm {0.67 in}

PB-10037

PB
 PB–14 Parking brake － Parking brake ASSY

Brembo type

Rear disc brake caliper ASSY LH

73 {744,53.8}

x2

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N*m {kgf*cm,ft*lbf} : Tightening torque
PB-10179

PB
 Parking brake － Parking brake ASSY
PB–15

Parking brake shoe hold-down spring pin

Parking brake
shoe wave washer

Parking brake shoe return

tension spring No. 2

Parking brake

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cable ASSY No. 3
Parking brake shoe pin

Parking brake shoe Parking brake

C-type washer shoe strut LH

Parking brake shoe

lever LH

Parking brake shoe strut

compression spring
Parking brake shoe kit

Parking brake shoe hold-down

compression spring

Parking brake shoe adjusting screw set LH

Parking brake shoe return tension spring No. 3

Non-reusable parts
PB
Disc brake grease (Molykote 44MA) Rear disc

PB-00417
 PB–16 Parking brake － Parking brake ASSY

Disassembly
1. Removal of rear tire
2. Disconnection of rear disc brake caliper ASSY LH
(1) Remove 2 bolts and then disconnect the rear disc brake caliper
from the rear axle carrier.
CAUTION:
Hang the brake caliper, using a wire or equivalent.

3. Removal of rear disc

(1) Put alignment marks on the rear disc and the axle hub.
Captions in illustration
C *a Alignment marks

(2) Release the parking brake and remove the rear disc.
NOTE:

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If it is difficult to remove the rear disc, insert a flat head screwdriver
from the rear disc service hole and rotate the adjusting screw to
contract the parking brake shoe.

Captions in illustration
*a Extend *b Contract

4. Removal of parking brake shoe return tension spring No.2 (installed to

the front side)
(1) Remove the parking brake shoe return tension spring No.2
 (installed to the front side).
Captions in illustration
*1 Parking brake she return tension spring No.2

PB
PB-00404
 Parking brake － Parking brake ASSY
PB–17

5. Removal of parking brake shoe return tension spring No.2 (installed to

the rear side)
(1) Remove the parking brake shoe return tension spring No.2
 (installed to the front side).
Captions in illustration
*1 Parking brake she return tension spring No.2

PB-00405

6. Removal of parking brake shoe strut compression spring

(1) Remove the parking brake shoe strut compression spring.
Captions in illustration
 *1 Parking brake shoe strut compression spring

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PB-00406

7. Removal of parking brake shoe hold-down compression spring

(installed to the front side)
(1) Remove the parking brake shoe hold-down compression spring
(installed to the front side).
Captions in illustration
*1 Parking brake shoe hold-down compression spring


PB-00407

8. Removal of parking brake shoe hold-down spring pin (installed to the front side)
(1) Remove the tension pin (installed to the front side).
9. Removal of parking brake shoe strut LH
(1) Spread the parking brake shoe kit outward with hands and remove
the parking brake shoe strut LH.
 Captions in illustration
*1 Parking brake shoe strut LH

PB
 PB–18 Parking brake － Parking brake ASSY

10. Removal of parking brake shoe hold-down compression spring

(installed to the rear side)
(1) Remove the parking brake shoe hold-down compression spring
 (installed to the rear side).
Captions in illustration
*1 Parking brake shoe hold-down compression spring

PB-00408

11. Removal of parking brake shoe hold-down spring pin (installed to the rear side)
NOTE:
Service the parking brake shoe hold-down spring pin (installed to the rear side) using the same procedures for the parking
brake shoe hold-down spring pin (installed to the front side).
12. Removal of parking brake shoe adjusting screw set LH
(1) Spread the parking brake shoe kit outward by hand and pull it out
from the lower side of the vehicle.

(2) Remove the parking brake shoe adjusting screw set LH from the
parking brake shoe kit. cardiagn.com

PB
 Parking brake － Parking brake ASSY
PB–19

13. Removal of parking brake shoe kit

(1) Remove the parking brake shoe kit from the parking brake shoe
return tension spring No.3.

14. Removal of parking brake shoe return tension spring No.3.

(1) Remove the parking brake shoe return tension spring No.3 from
the parking brake shoe kit.

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15. Disconnection of parking brake shoe lever LH
(1) Disconnect the parking brake shoe lever LH.

16. Removal of parking brake shoe C type washer

(1) As shown in the figure, spread the parking brake shoe C type
washer and remove it from the parking brake shoe kit.

17. Removal of parking brake shoe wave washer

(1) Remove the parking brake shoe wave washer.
18. Removal of parking brake shoe pin
(1) Remove the parking brake shoe pin.

PB
 PB–20 Parking brake － Parking brake ASSY

Inspection
1. Rear disc inner diameter check
(1) Using a caliper, check the inner diameter of the disc.
Limit: 191.0mm {7.52 in}
Reference value: : 190.0mm {7.48 in} (New)

2. Parking brake shoe lining thickness check

Limit: 1.5mm {0.059in}
Reference value: : 3.5 mm {0.138 in} (New)
CAUTION:
Replace the right and left parts as a set. (for preventing the unequal distri-
bution of the braking force)

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Assembly
1. Applying grease to backing plate
(1) Apply a thin coat of brake grease to the contacting part of the
backing plate shoe.
Captions in illustration

Brake grease (Molykote 44MA)

2. Installation of parking brake shoe pin

(1) Install the parking brake shoe pin to the parking brake shoe kit.
3. Installation of parking brake shoe lever LH
(1) Apply a thin coat of non-melting lubrication to the contacting part of the parking brake shoe lever LH and the parking
brake shoe pin.
(2) Install the parking brake shoe lever LH to the parking brake shoe kit.
4. Installation of parking brake shoe wave washer
(1) Install the parking brake shoe wave washer.
5. Installation of parking brake shoe C type washer
(1) Install a new parking brake shoe C type washer.

PB
Parking brake － Parking brake ASSY
PB–21

(2) Using a pliers, crimp the parking brake shoe C type washer.

6. Installation of parking brake cable ASSY No.3

(1) Using a pair of needle nose pliers, install the parking brake cable
ASSY No.3 to the parking brake shoe lever LH.

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7. Installation of parking brake shoe return tension spring No.3.
(1) Install the parking brake shoe return tension spring No.3 to the
parking brake shoe kit.

8. Installation of parking brake shoe kit (installed to the front side)

(1) Install the parking brake shoe kit to the parking brake shoe return
tension spring No.3.

PB
 PB–22 Parking brake － Parking brake ASSY

9. Installation of parking brake shoe adjusting screw set LH

(1) Apply disc brake grease to the threaded portion of the parking
brake shoe adjusting screw set LH and the piece-attaching part.
(2) Install the parking brake shoe adjusting screw set LH to the park-
ing brake shoe kit.
CAUTION:
The direction of parking brake shoe adjusting screw set is different for
RH and LH. Be careful not to install them in the wrong direction.
Captions in illustration

Disc brake grease (Molykote 44MA)

Front of the vehicle (LH side)

Rear of the vehicle (RH side)

(3) Spread the parking brake shoe kit outward by hand and align it to
the backing plate.

10. Installation of parking brake shoe hold-down spring pin (installed to the rear side)
(1) Install the parking brake shoe hold-down spring pin (installed to the rear side) to the backing plate.
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11. Installation of parking brake shoe hold-down compression spring
(installed to the rear side)
(1) Install the parking brake shoe hold-down compression spring
 (installed to the rear side).
Captions in illustration
*1 Parking brake shoe hold-down compression spring

PB PB-00408
 Parking brake － Parking brake ASSY
PB–23

12. Installation of parking brake shoe strut LH

(1) Spread the parking brake shoe kit outward by hand and install the
parking brake shoe strut LH.
 Captions in illustration
*1 Parking brake shoe strut LH

(2) Install the parking brake shoe kit to the specified position.

13. Installation of parking brake shoe hold-down spring pin (installed to the front side)
(1) Install the parking brake shoe hold-down spring pin (installed to the front side) to the backing plate.
14. Installation of parking brake shoe hold-down compression spring
(installed to the front side)
(1) Install the parking brake shoe hold-down compression spring
(installed to the rear side).
Captions in illustration
*1 Parking brake shoe hold-down compression spring


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PB-00407

15. Installation of parking brake shoe strut compression spring

(1) Install the parking brake shoe strut compression spring to the parking brake shoe strut LH.
16. Installation of parking brake shoe return tension spring No.2 (installed to the rear side)
(1) Install the parking brake shoe return tension spring No.2 (installed to the rear side).
17. Installation of parking brake shoe return tension spring No.2 (installed to the front side)
(1) Install the parking brake shoe return tension spring No.2 (installed to the front side).
18. Parking brake installation check
(1) Make sure that each part is installed correctly.

C D

PB
 PB–24 Parking brake － Parking brake ASSY

Captions in illustration
*a LH side *b RH side

Front of vehicle - -

19. Installation of rear disc

(1) Align the marks on the rear disc and the axle hub, and install the
rear disc.
C Captions in illustration
*a Alignment marks

NOTE:
If the rear disc has been replaced with new one, this procedure is
not required.

20. Clearance adjustment of disc and lining

(1) Using a wheel nut, secure the rear disc.
(2) Remove the service hole plug of the rear disc, and turn the rear disc until the service hole is aligned to the adjusting

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screw.
(3) Using a flat tip screwdriver, turn the adjusting screw in the extension direction until the parking brake shoe is in close con-
tact with the disc.

Captions in illustration
*a Extend *b Contract

(4) Turn the adjusting screw in the contraction direction until the rear disc rotates lightly.
NOTE:
Standard number of notches to return: 10
(5) Check for brake drag.
(6) Remove the wheel nut.

PB
 Parking brake － Parking brake ASSY
PB–25

21. Connection of rear disc brake caliper ASSY LH

(1) Using 2 new bolts, install the rear disc brake caliper ASSY LH.
Standard value:Width across flat 14 mm {0.55 in}
T=66N·m {673kgf·cm} {48.7ft·lbf}
Width across flat 17 mm {0.67 in}
T=110N·m {1122kgf·cm} {81.1 ft·lbf}
CAUTION:
• Do not twist the flexible hose.
• Make sure that there is no foreign matter or damage on the
threaded portion.

22. Connection of rear disc brake caliper ASSY LH (brembo type)

(1) Using 2 bolts, install the rear disc brake caliper ASSY LH.
Standard value:T=73N·m {744kgf·cm} {53.8ft·lbf}
CAUTION:
• Do not twist the flexible hose.
• Make sure that there is no foreign matter or damage on the threaded portion.
23. Parking brake lever stroke check (Refer to PB - 2)
24. Adjustment of parking brake (Refer to PB - 2)
25. Installation of rear tire

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Standard value:T=120N·m {1224kgf·cm} {88.5ft·lbf}

PB
 PB–26 Parking brake － Parking brake switch ASSY

Parking brake switch ASSY

Parking brake
Brake

Exploded view

Parking brake
switch ASSY

1.5 {15,1.1}

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N•m {kgf•cm, ft•lbf} : Tightening torque

PB-0041

Removal
1. Removal of console box ASSY (Refer to IT - 33)
2. Removal of parking brake switch ASSY
(1) Disconnect the connector.

(2) Remove the screw and parking brake switch ASSY from the park-
ing brake lever ASSY.

Installation
1. Installation of parking brake switch ASSY
(1) Install the parking brake switch ASSY to the parking brake lever ASSY with screw.
Standard value:T=1.5N·m {15kgf·cm} {1.1 ft·lbf}
(2) Connect the connector.
2. Installation of console box ASSY (Refer to IT - 38)

PB
 Parking brake － Parking brake switch ASSY
PB–27

Unit inspection
1. Parking brake switch ASSY check
(1) Measure the resistance between the parking brake switch ASSY
and the chassis ground.
Captions in illustration

ON

OFF

Resistance
Inspection terminals Inspection conditions Standard value
When shaft is free (ON) Less than 1 Ω
1(+) - chassis ground When shaft is pressed in
10 k Ωor more
(OFF)

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PB
 PB–28 Parking brake － Parking brake switch ASSY

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PB