EXTFILE134712701

BRAKE SYSTEM
CONTENTS
TOOLS.......................................................................................................... BR-1
BRAKE ASSEMBLY BAL41 TYPE ............................................................... BR-3
CONSTRUCTION .................................................................................... BR-3
DISASSEMBLY AND REASSEMBLY....................................................... BR-5
INSPECTION ......................................................................................... BR-13
REPAIR AND REPLACEMENT.............................................................. BR-16
ADJUSTMENT ....................................................................................... BR-17
BRAKE ASSEMBLY BPL41 TYPE ............................................................. BR-19
CONSTRUCTION .................................................................................. BR-19
DISASSEMBLY AND REASSEMBLY..................................................... BR-23
INSPECTION ......................................................................................... BR-35
REPAIR AND REPLACEMENT.............................................................. BR-40
ADJUSTMENT ....................................................................................... BR-42
BRAKE CHAMBER FRONT ....................................................................... BR-45
CONSTRUCTION .................................................................................. BR-45
REMOVAL AND INSTALLATION ........................................................... BR-46
DISASSEMBLY AND REASSEMBLY..................................................... BR-48 BR
INSPECTION ......................................................................................... BR-61
BRAKE CHAMBER REAR.......................................................................... BR-63
CONSTRUCTION .................................................................................. BR-63
REMOVAL AND INSTALLATION ........................................................... BR-65
DISASSEMBLY AND REASSEMBLY..................................................... BR-67
INSPECTION ......................................................................................... BR-89
SERVICE DATA .......................................................................................... BR-91
SPECIFICATIONS.................................................................................. BR-91
UNIT NAME............................................................................................ BR-91
APPLICATION ........................................................................................ BR-92
OUTLINE OF BRAKE SYSTEM............................................................. BR-96
SERVICE DATA.................................................................................... BR-108
TIGHTENING TORQUE ....................................................................... BR-110
TOOLS
TOOLS
Tool name and number Description Shape
Used to replace the lining or remove the shoe assem-

Height gauge
bly, set shoe height to the standard value.
99640 Z0003
(For BAL41, BPL41)
Spring setter (Replacer) Used to remove and install the expander’s wedge
99828 Z0062 assembly.
Cage setter (Replacer)

Used to assemble the expander’s cage.
99828 Z0061
Boot setter (Replacer)

Used to assemble the expander’s boot.
99828 Z0063
Adapter Used to measure the expander’s clip retaining torque

99865 Z000A and the sleeve’s rotation torque.
Set gauge Used to check the brake chamber stem’s set size and
99862 Z0001 to determine the number of washers for adjustment.
Return spring tool To be used to install and remove the return spring.
99867 Z0003 (For BAL41, BPL41)
BR-1
TOOLS
Used to removal/install return spring

Return spring tool assembly
(inner side : BPL41)
99867 Z0002
S-Camshaft type for rear front brake
1. 99868 Z0000
1. Handle
2. 99868 Z0002
2. Hanger
3. 99524 Z0000
3. Spacer
BR-2
BRAKE ASSEMBLY BAL41 TYPE

CONSTRUCTION
BAL41 type
BR-3
Expander
BR-4
DISASSEMBLY AND REASSEMBLY

BAL41 type
Disassembly sequence (Reassembly Sequence is in the reverse order of disassembly.)

1 Return spring 2 Bolt 3 Lock washer
4 Lock plate 5 Anchor pin 6 Brake shoe assembly
7 Rivet 8 Brake lining 9 Retaining ring
10 Return spring pin 11 Bolt 12 Pivot plate
13 Bushing 14 Bolt 15 Brake chamber assembly
16 O-ring 17 Bolt 18 Expander assembly
19 Bolt 20 Dust cover 21 Grommet
22 Brake bracket 23 Wheel speed sensor 24 Sensor holder
25 Sensor bracket
BR-5
Expander
Disassembly sequence (Reassembly Sequence is in the reverse order of disassembly.)

1 Boot 2 Clip 3 Adjustment screw
4 Spring cage 5 Spring 6 Drive ring
7 Screw 8 Sleeve assembly 9 Retaining ring
10 Spring retainer 11 Spring 12 Retaining ring
13 Boot 14 Cap assembly 15 Roller
16 Cage 17 Wedge assembly 18 Housing
BR-6
Key point of disassembly

1. Remove the return spring assembly, using a return spring tool
(99867 Z0003).
2. Remove the boot by inserting a flat-blade screwdriver between

the housing and the boot.
CAUTION
 Once the boot is removed, it cannot be reused.
3. To remove the clip from the adjustment screw assembly, hold

the clip and upward with a flat-blade screwdriver and pull the
clip out.
CAUTION
 Be careful not to damage the boot.
 Once the clip is removed, it cannot be reused.
4. To remove the cage from the housing, put the tip of the driver
into the slit of the cage, raise the cage having the housing as a
support, then remove the cage.
CAUTION
 During the procedure, make sure to hold the cage by
hand to prevent the spring under the case from popping
out.
5. Remove the drive ring and spring.
BR-7
6. After removing the screw, pull out the sleeve assembly. The
sleeve assembly cannot be disassembled.
7. Tighten the spring setter as a tool (99828 Z0062) to the hous-

ing with a bolt and tighten the spring, then remove the retain-
ing ring.
8. After removing the spring setter as a tool, remove the spring

retainer and spring.
9. Remove the retaining ring from the housing, and take out the
wedge assembly.
10. Remove the cage and roller from the wedge. When doing this,
remove the roller by opening the cage so that the cage is not
deformed.
CAUTION
 Do not open the opening of the cage for 26 mm or more.
 There should not be scratches on the wedge and the
outside of the roller.
BR-8
Key point of reassembly

1. Open the cage and reassemble the roller to it, then assemble it
to the wedge. Coat the engagement contacting areas of the
roller, cage and wedge with Darina grease RL2.
CAUTION
2. Assemble the boot and the cap assembly to the wedge.

When doing this, coat the wedge’s axis and the installation
area of the boot contacting it with Darina grease RL2.
3. Fill the (A) at the bottom of the housing with Darina grease
RL2.
4. Put the wedge assembly into the housing and fit the retaining
ring into the housing groove.
5. Set the spring and the retainer to the wedge assembly and
tighten the spring with the spring setter as a tool (99828
Z0062), then put the retaining ring into the wedge.
BR-9
6. Fill the housing and the  area on the sleeve out-of-round-
ness with Darina grease RL2.
 The housing’s drive ring sheet surface.
 The housing sleeve’s sliding area and the tappet’s prodding
area.
 The tappet’s area contacting the roller and its out-of-round-
ness.
 The sleeve’s out-of-roundness, its gear area and thread.
7. After inserting the sleeve assembly into the housing, tighten

the screw.
Tightening torque [N•m {kgf•m}]: 12 - 18 {1.2 - 1.8}
NOTE
 Align the housing’s screw mounting hole and the tap-
pet’s groove.
 Coat the screw with Loctite 242 or Three Bond 2415 for
the amount for approximately 2 threads.
CAUTION
 The sleeve assembly differs depending on the type of
the brake. Check it before the installation.
8. Assemble the drive ring and the spring, then fit the cage into
the housing groove with a flat-blade screwdriver and the cage
setter as a tool (99828 Z0061).
BR-10
9. Assemble the boot to the screw. Coat the boot’s area contact-
ing the screw and the (A) thread with Darina grease RL2.
NOTE
 Make sure to securely put the boot into the screw’s
groove.
10. Screw in the screw down to the position where it sticks out of
the housing edge for approximately 20 mm. When doing this,
pull the screw and confirm that the sleeve slides. After this,
press fit the boot with the boot setter as a tool (99828 Z0063)
(slightly hit it with a plastic hammer, etc.).
CAUTION
11. Fully screw in the screw, then return it for 2 rotations in the
extension direction, and install the clip to the screw’s gear.
Install the clip from the anchor pin side toward the lining side.
CAUTION
BR-11
12. Fill the place indicated in the figure with Darina grease RL2.
13. Make the direction of the adjust screw assembly parallel to the
brake bracket. Make sure that the brake shoe assembly is
within the wide across flat of the adjust screw assembly.
14. The expander assembly has different convergence stroke

depending on the type of the brake. According to the identifica-
tion in the figure right, install a proper expander assembly for
each brake.
15. Coat the anchor pin’s groove, the brake shoe bush’s inside,
and shoe’s area contacting the brake bracket with grease.
CAUTION
 Do not let the grease stick to the brake lining.
16. Install the return spring with the return spring tool (99867
Z0003).
BR-12
INSPECTION
 Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
 If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
BRAKE DRUM
Check if there are wear (streaks, deviated wear, stepped wear
inside the drum), heat cracks, other cracks, or damage in the brake
drum.
 If the heat crack or the stepped wear is not so serious, repair it
by cutting the drum surface anew. If it cannot be repaired by
cutting, replace it with new one.
 Check not only the lining’s sliding surface, but also the hub’s
installation area (around the hub bolt, etc.).
BRAKE DRUM INSIDE DIAMETER, BRAKE DRUM

ROUNDNESS
Check the inside diameter of brake drum at four points.
If the difference between the maximum and minimum values
exceeds the service limit, correct the inside surface of drum by
machining.
Unit: mm
Item Maintenance standard Service limit
Inside diameter 410 414
Roundness 0.025 or less 0.2
BRAKE SHOE
Thickness of brake lining (A)
Unit: mm
Maintenance standard Service limit
16 5
Anchor pin outside diameter

Unit: mm
34.90 - 34.94 34.85
BR-13
Brake shoe bushing inside diameter

Unit: mm
35.00 - 35.05 35.15
Clearance between anchor pin and brake shoe bush-

ing
Unit: mm
0.06 - 0.15 0.30
RETURN SPRING
Return spring tension
Unit: N {kgf}
Maintenance standard Service limit Remarks
593 - 724 {60.5 - 73.8} – When spring length is 229.5 mm
Return spring free length

Unit: mm
203.7 –
EXPANDER
Check if there are deformation or cracks on the adjust screw
assembly’s clip or breakage on the boot.
CAUTION
 If there is something wrong with the clip, the automatic
adjuster function does not properly work.
BR-14
Adjust screw assembly’s clip holding torque

Fix the adjust screw assembly’s screw with a vise, and set the
adapter as a tool (99865 Z000A) to the clip.
Install a torque wrench to the adapter, and measure the torque
when the clip has started rotating.
CAUTION
 Insert a buffer material (rubber sheet, etc.) to protect the
screw from being damaged. If the screw is damaged,
the automatic adjuster function does not properly work.
Unit: N•m {kgf•m}
1.5 - 5.0 {0.15 - 0.5} –
Revolution torque of sleeve assembly

Fix the sleeve assembly with a vise, and attach the adapter as a
tool (99865 Z000A) to the tappet.
Attach the torque wrench to the adapter, and measure the torque
when the tappet starts rotating. NOTE that the torque measurement
of the counterclockwise should be used only to confirm the mainte-
nance standard, and avoid the use of excessive torque.
CAUTION
 Insert a buffer material (rubber sheet, etc.) in order to
protect the sleeve’s screw from being damaged. If the
sleeve’s screw is damaged, the automatic adjuster func-
tion does not properly work.
0.6 {0.06} or less – Clockwise revolution
2.0 {0.2} or more – Counterclockwise revolution
Spring tension
Unit: N {kgf}
When installation
78.5 {8.0} 73.6 {7.5} or less
length is 11.3 mm
Wedge spring tension

Unit: N {kgf}
When installation
147 {15.0} 132.3 {13.3} or less
length is 105.8 mm
Wear of housing inside diameter

Unit: mm
38.1 - 38.2 –
BR-15
REPAIR AND REPLACEMENT

PROCEDURES TO REPLACE BRAKE LINING
1. Slightly drill the swaged areas for riveting from brake shoe
side, remove rivets with a punch or the like, and then remove
the lining.
NOTE
 Take care not to pierce the brake shoe.
1 Drill 2 Rivet
3 Brake shoe 4 Brake lining
2. Align holes on lining to those on shoe, and insert and swage

rivets. Swaging rivets should be started from the center and
then proceed to both sides, alternately.
NOTE
 In case of improper assembly, cracked or wobbled lining
mmay take place.
 Flaws and projections on the contacting surface of brake
shoe lining must be removed in advance.
1 Rivet guide 2 Brake shoe 3 Rivet

4 Brake lining 5 Holder 6 Punch
7 Finish punch
BR-16
BRAKE SHOE BUSHING

1. Drive out the bushing.
2. Remove all dirt and foreign matter from the brake shoe bush-
ing hole.
3. Tap the bushing into the brake shoe. After press-fitting the
bushing, measure the bushing inside diameter. If it is over
35.00 to 35.05 mm, ream the bushing so that the inside diame-
ter is within the standard value.
NOTE
 Do not coat the shoe bushing with grease or oil.
ADJUSTMENT
SHOE HEIGHT (CLEARANCE) ADJUSTMENT
When replacing the lining or removing the shoe assembly, set shoe
height to the standard value. Set the height with a height gauge
(99640 Z0003) before attaching them to the drum.
NOTE
 Shoe clearance set with the height gauge is adjusted to
the standard value (0.7 mm). Therefore, primary adjust-
ment of shoe clearance is not required after assembly.
SHOE CLEARANCE ADJUSTMENT (PRIMARY

ADJUSTMENT)
1. Jack up the vehicle’s spindle to be adjusted, and check that
there is no backlash in the hub bearing.
2. Remove the dust cover.
3. Insert a 0.7 mm feeler gauge from the wear check hole.
With the gauge inserted, turn the adjuster in the direction
shown by the arrow until it hits the end, then remove the feeler
gauge.
4. Depress the brake pedal several times. Check for drag when
the drum is rotated by hand.
NOTE
 When inserting a screwdriver, be careful not to damage
the dust boot on the wheel cylinder.
 Check clearance at two check holes.
Unit: mm
0.1 - 1.2 –
* The maintenance standard indicates the clearance in use.
5. Install the dust cover firmly.
BR-17
REPLACEMENT TIMING OF BRAKE LINING

Remove the rubber plugs from the check holes, and inspect the
wear status of the lining. If the brake lining is worn to the stepped
point, replace it. There are two check holes per wheel. Be sure to
inspect at both check holes.
To install the brake shoe, check the pivot plate’s shape for adjusting
the shoe clearance.
If the cast shoe pivot plate has been removed, install it after coating
the bolt thread with Loctite #241 (or equivalent).
BR-18
BRAKE ASSEMBLY BPL41 TYPE

CONSTRUCTION
BPL41 type
Wedge type
BR-19
Camshaft type (Rear front)
BR-20
Camshaft type (Rear rear)
BR-21
Expander
BR-22

BPL41 type
Wedge type
Disassembly sequence (Assembly is done in the reverse sequence of disassembly)

1 Return spring 2 Bolt 3 Lock washer
7 Rivet 8 Brake lining 9 Retaining ring
10 Return spring pin 11 Bolt 12 Pivot plate
13 Bushing 14 Bolt 15 Dust cover
16 Chamber seal 17 Grommet 18 Bolt
19 Brake chamber assembly 20 O-ring 21 Bolt
22 Expander assembly 23 Brake bracket 24 Bolt
25 Washer 26 Bolt 27 Sensor bracket
28 Sensor clamp 29 Wheel speed sensor 30 Sensor holder
BR-23
Camshaft type (Rear front)

1 Return spring (outer) 2 Return spring (inner) 3 Return spring pin
4 Lock washer 5 Lock plate 6 Anchor pin
7 Brake shoe assembly 8 Clip 9 Roller pin
10 Roller 11 Retaining ring 12 Camshaft spacer
13 Slack adjuster assembly 14 Camshaft spacer 15 Felt ring
16 Camshaft 17 Ring 18 Dust cover
19 Brake chamber assembly 20 Brake chamber bracket 21 Brake bracket
22 Vehicle speed sensor
assembly
BR-24
Camshaft type (Rear rear)

1 Return spring 2 Return spring pin 3 Lock washer
7 Clip 8 Roller pin 9 Roller
10 Cotter pin 11 Clevis pin 12 Retaining ring
13 Camshaft spacer 14 Slack adjuster assembly 15 Camshaft spacer
16 Clip 17 Camshaft spacer 18 Clip
19 Camshaft 20 Camshaft bracket 21 Shim
22 Back plate 23 Ring 24 Brake bracket
25 Brake chamber assembly 26 Vehicle speed sensor
assembly
BR-25
Expander
Disassembly sequence (assembly is done in the reverse sequence of disassembly)

1 Boot 2 Clip 3 Adjustment screw
4 Spring cage 5 Spring 6 Drive ring
7 Screw 8 Sleeve assembly 9 Retaining ring
10 Spring retainer 11 Spring 12 Retaining ring
13 Boot 14 Cap assembly 15 Roller
16 Cage 17 Wedge assembly 18 Housing
BR-26

<Wedge type and camshaft type>
1. Remove the return spring assembly [outer for camshaft type
(rear front only)], using a return spring tool (99867 Z0003).
2. camshaft type (Rear front) only

Remove the return spring assembly (inner) using return spring
tool (99867 Z0002). Attach the hanger to the spring tip and
turn the handle. When a clearance appears between the pin
and spring tip, extract the pin.
<Wedge type>
1. Remove the boot by inserting a flat-blade screwdriver between
the housing and the boot.
CAUTION
2. To remove the clip from the adjustment screw assembly, hold

the clip and upward with a flat-blade screwdriver and pull the
clip out.
CAUTION
BR-27
3. To remove the cage from the housing, put the tip of the driver
into the slit of the cage, raise the cage having the housing as a
support, then remove the cage.
CAUTION
 During the procedure, make sure to hold the cage by
hand to prevent the spring under the case from popping
out.
4. Remove the drive ring and spring.
5. After removing the screw, pull out the sleeve assembly. The
sleeve assembly cannot be disassembled.
6. Tighten the spring setter as a tool (99828 Z0062) to the hous-

ing with a bolt, and tighten the spring, then remove the retain-
ing ring.
7. After removing the spring setter as a tool, remove the spring

retainer and spring.
BR-28
8. Remove the retaining ring from the housing, and take out the
wedge assembly.
9. Remove the cage and roller from the wedge. When doing this,
remove the roller by opening the cage so that the cage is not
deformed.
CAUTION
 There should not be scratches on the wedge and the
outside of the roller.

<Wedge type>
1. Open the cage and reassemble the roller to it, then assemble it
to the wedge.
Coat the engagement contacting areas of the roller, cage and
wedge with Darina grease RL2.
CAUTION
2. Assemble the boot and the cap assembly to the wedge.

When doing this, coat the wedge’s axis and the installation
area of the boot contacting it with Darina grease RL2.
BR-29
3. Fill the (A) at the bottom of the housing with Darina grease
RL2.
4. Put the wedge assembly into the housing and fit the retaining
ring into the housing groove.
5. Set the spring and the retainer to the wedge assembly and
tighten the spring with the spring setter as a tool (99828
Z0062), then put the retaining ring into the wedge.
6. Fill the housing and the  area on the sleeve out-of-round-
ness with Darina grease RL2.
 The housing’s drive ring sheet surface.
 The housing sleeve’s sliding area and the tappet’s prodding
area.
 The tappet’s area contacting the roller and its out-of-round-
ness.
 The sleeve’s out-of-roundness, its gear area and thread.
7. After inserting the sleeve assembly into the housing, tighten

the screw.
NOTE
 Align the housing’s screw mounting hole and the tap-
pet’s groove.
 Coat the screw with Loctite 242 or Three Bond 2415 for
the amount for approximately 2 threads.
BR-30
CAUTION
 The sleeve assembly differs depending on the type of
brake. Check it before the installation.
8. Assemble the drive ring and the spring, then fit the cage into
the housing groove with a flat-blade screwdriver and the cage
setter as a tool (99828 Z0061).
9. Assemble the boot to the screw. Coat the boot’s area contact-
ing the screw and the (A) thread with Darina grease RL2.
NOTE
 Make sure to securely put the boot into the screw’s
groove.
10. Screw in the screw down to the position where it sticks out of
the housing edge for approximately 20 mm.
When doing this, pull the screw and confirm that the sleeve
slides. After this, press fit the boot with the boot setter as a tool
(99828 Z0063) (slightly hit it with a plastic hammer, etc.).
CAUTION
BR-31
11. Fully screw in the screw, then return it for 2 rotation in the
extension direction, and install the clip to the screw’s gear.
Install the clip from the anchor pin side toward the lining side.
CAUTION
12. Fill the place indicated in the figure with Darina grease RL2.
13. Make the direction of the adjust screw assembly parallel to the
brake bracket. Make sure that the brake shoe assembly is
within the wide across flat of the adjust screw assembly.
14. The expander assembly has different convergence stroke

depending on the type of the brake. According to the identifica-
tion in the figure right, install a proper expander assembly for
each brake.
<Camshaft type>
1. After inserting the camshaft, check that the camshaft can be
rotated smoothly, then tighten the brake chamber bracket.
BR-32
2. Before installing the brake chamber assembly, make sure

dimension L is 60 mm (rear front) or 360 mm (rear rear).
3. Insert the slack adjuster into the camshaft. Move the lever
back and forth with a hand and make sure that there is no jam-
ming on the camshaft.
4. Turn the worm screw of the slack adjuster clockwise and align
the bushing hole with the clevis pin hole. Apply the appropriate
amount of grease to the clevis pin and insert it into the pin
hole. Fix it with a cotter pin.
NOTE
 If the worm screw of the slack adjuster is turned exces-
sively and the bushing hole is not correctly aligned, turn
back the screw to a large degree to allow for an inner
play and then turn it again.
 When the worm screw is turned counterclockwise, reac-
tion force and gear engagement noise are generated.
This is not a failure.
5. Install the roller pin paying attention to its installation direction,

and check the roller for smooth rotation.
NOTE
 Do not apply grease to any part of the roller and roller
pin.
BR-33
<Wedge type and camshaft type>

1. Coat the anchor pin’s groove, the brake shoe bush’s inside,
and shoe’s area contacting the brake bracket with grease.
CAUTION
 Do not let the grease stick to the brake lining.
 In case of replacing the brake shoe from cast type to
sheet metal type, must be performed for left and right
wheels at the same time. (Wedge type only)
CAUTION
 Trailing shoe of sheet metal type has a identification
hole for prevention of faulty installation with leading
shoe. Check whether there is identification hole, before
the installation. (Wedge type only)
2. Install the return spring assembly using return spring tool

(99867 Z0002).
3. After tightening the bolt, bend the lock washher sharply

against the bolt head.
Tightening torque [N•m {kgf•m}]: 20.1 - 33.9 {2.1 - 3.5}
4. Install the return spring [outer for camshaft type (rear front)
only] with the return spring tool (99867 Z0003).
BR-34
INSPECTION
BRAKE DRUM
Check if there are wear (streaks, deviated wear, stepped wear
inside the drum), heat cracks, other cracks, or damage in the brake
drum.
 If the heat crack or the stepped wear is not so serious, repair it
by cutting the drum surface anew. If it cannot be repaired by
cutting, replace it with new one.
 Check not only the lining’s sliding surface, but also the hub’s
installation area (around the hub bolt, etc.).
BRAKE DRUM INSIDE DIAMETER, BRAKE DRUM

ROUNDNESS
Check the inside diameter of brake drum at four points.
If the difference between the maximum and minimum values
exceeds the service limit, correct the inside surface of drum by
machining.
Unit: mm
Inside diameter 410 414
BRAKE SHOE
Thickness of brake lining (A)
Unit: mm
16 5
BR-35
Anchor pin outside diameter

Unit: mm
Wedge type 34.90 - 34.94 34.85
Camshaft type 29.895 - 29.93 29.85
Brake shoe bushing inside diameter

Unit: mm
Wedge type 35.00 - 35.05 35.15
Camshaft type 30.00 - 30.05 30.15
Clearance between anchor pin and brake shoe bush-

ing
Unit: mm
Wedge type 0.06 - 0.15 0.30
Camshaft type 0.07 - 0.20 0.25
Brake shoe roller inside diameter

Unit: mm
Camshaft type 20.3 20.7
Brake shoe roller outside diameter

Unit: mm
BR-36
Brake shooe roller pin outside diameter

Unit: mm
Clearance between brake shoe roller and brake shoe

roller pin
Unit: mm
CAMSHAFT
Camshaft bushing inside diameter
Unit: mm
Camshaft outside diameter

Unit: mm
Clearance between camshaft bushing and camshaft

Unit: mm
BR-37
RETURN SPRING
Return spring tension
Unit: N {kgf}
Item Maintenance standard Service limit Remarks
Wedge type 541.6 - 635.6 {55.24 - 64.83} – When spring length is 230.0 mm
Outer 549 - 637 {56.0 - 65.0} – When spring length is 219.0 mm
Camshaft Rear front
Inner 198 - 233 {20.2 - 23.8} – When spring length is 252.5 mm
type
Rear rear 701 - 809 {71.5 - 82.5} – When spring length is 219.0 mm
Return spring free length

Unit: mm
Wedge type 200.8 –
Outer 195.9 –
Camshft Rear front
Inner 242.6 –
type
Rear rear 186.7 –
EXPANDER
Check if there are deformation or cracks on the adjust screw
assembly’s clip or breakage on the boot.
CAUTION
 If there is something wrong with the clip, the automatic
adjuster function does not properly work.
Adjust screw assembly’s clip holding torque

Fix the adjust screw assembly’s screw with a vise, and set the
adapter as a tool (99865 Z000A) to the clip.
Install a torque wrench to the adapter, and measure the torque
when the clip has started to rotating.
CAUTION
 Insert a buffer material (rubber sheet, etc.) to protect the
screw from being damaged. If the screw is damaged,
the automatic adjuster function does not properly work.

Maintenance Standard Service limit
1.5 - 5.0 {0.15 - 0.5} –
BR-38
Revolution torque of sleeve assembly

Fix the sleeve assembly with a vise, and attach the adapter as a
tool (99865 Z000A) to the tappet. Attach the torque wrench to the
adapter, and measure the torque when the tappet starts rotating.
NOTE that the torque measurement of the counterclockwise should
be used only to confirm the maintenance standard, and avoid the
use of excessive torque.
CAUTION
 Insert a buffer material (rubber sheet, etc.) in order to
protect the sleeve’s screw from being damaged. If the
sleeve’s screw is damaged, the automatic adjuster func-
tion does not properly work.

2.0 {0.2} or more – Counterclockwise revolution
Spring tension
Unit: N {kgf}
When installation
78.5 {8.0} 73.6 {7.5} or less
length is 11.3 mm
Wedge spring tension

Unit: N {kgf}
When installation
147 {15.0} 132.3 {13.3} or less
length is 105.8 mm

Unit: mm
38.1 - 38.2 –
BR-39
REPAIR AND REPLACEMENT

PROCEDURES TO REPLACE BRAKE LINING
Replacement of brake lining
1. Slightly drill the swaged areas for riveting from brake shoe
side, remove rivets with a punch or the like, and then remove
the lining.
NOTE
 Take care not to pierce the brake shoe.
1 Drill 2 rivet
3 Brake shoe 4 Brake lining
2. Align holes on lining to those on shoe, and insert and swage

rivets. Swaging rivets should be started from the center and
then proceed to both sides, alternately.
NOTE
 In case of improper assembly, cracked or wobbled lining
may take place.
 Flaws and projections on the contacting surface of brake
shoe lining must be removed in advance.
1 Rivet guide 2 Brake shoe

3 Rivet 4 Brake lining
5 Holder 6 Punch
7 Finish punch
BR-40
Brake shoe bushing

1. Drive out the bushing.
2. Remove all dirt and foreign matter from the brake shoe bush-
ing hole.
3. Tap the bushing into the brake shoe. After press-fitting the
bushing, measure the bushing inside diameter. If it is over
35.00 to 35.05 mm (wedge type) and 30.00 to 30.05 mm (cam-
shaft type), ream thebushing so that the inside diameter is
within the standard value.
NOTE
 Do not coat the shoe bushing with grease or oil.
Camshaft bushing
1. Remove the oil seal from the brake bracket.
2. Drive out the camshaft bushing from the brake bracket.
3. Remove all dirt and foreign matter from the brake bracket
bushing hole.
4. Press-fit the new bushing and oil seal onto the brake bracket.
After press-fitting the bushing, measure the bushing inside
diameter. If it is over 40.00 to 40.03 mm, ream the bushing so
that the inside diameter is within the standard value.
5. Press-fit the new bushing onto the brake bracket. After press-
fitting the bushing, measure the bushing inside diameter. If it is
over 40.00 to 40.03 mm, ream the bushing so that the inside
diameter is within thestandard value.
BR-41
ADJUSTMENT
SHOE HEIGHT (CLEARANCE) ADJUSTMENT (WEDGE

TYPE)
When replacing the lining or removing the shoe assembly, set shoe
height to the standard value. Set the height with a height gauge
(99640 Z0003) before attaching them to the drum.
NOTE
 Shoe clearance set with the height gauge is adjusted to
the standard value (0.7 mm). Therefore, primary adjust-
ment of shoe clearance is not required after assembly.
ADJUSTMENT OF SHOE CLEARANCE (INITIAL

ADJUSTMENT) (WEDGE TYPE)
1. Jack up the vehicle’s spindle to be adjusted, and check that
there is no backlash in the hub bearing.
2. Remove the dust cover.
3. Insert a 0.7 mm feeler gauge from the wear check hole.
With the gauge inserted, turn the adjuster in the direction
shown by the arrow until it hits the end then remove the feeler
gauge.
4. Depress the brake pedal several times. Check for drag when
the drum is rotated by hand.
NOTE
 When inserting a screwdriver, be careful not to damage
the dust boot on the wheel cylinder.
 Check clearance at two check holes.
Unit: mm
0.1 - 1.2 –
* The maintenance standard indicates the clearance in use.
5. Install the dust cover firmly.
BR-42
ADJUSTING THE BRAKE CHAMBER PUSH ROD

STROKE (CAMSHAFT TYPE)
1. Jack up the axle and make sure that there is no play at the
wheel bearing.
2. Measure the push rod stroke when the brake pedal is
depressed with normal pressure.
Unit: mm
Maintenance
Item Service limit
standard
*170
Push rod stroke 30 45
*125
NOTE
 Referring to * : 170 mm and 125 mm are dimensions (L)
between the centers of holes in both ends of the slack
adjuster.
3. Adjust the push rod stroke if it is outside the allowable limit.

 Check the installation length of the brake chamber push rod.
Unit: mm
Item Push rod set length L Remarks
Rear front 60 Distance from the chamber end
face to the center of clevis pin
Rear rear 360 hole
 After adjusting the installation length of the push rod, measure

the push rod again by pressing the brake pedal.
 If the push rod stroke is outside the allowable limit, fully tighten
the adjusting bolt of the slack adjuster, then back off two clicks.
 rotate the brake drum by hand to see that the brake shoe is not
touching the brake drum.
BR-43
REPLACEMENT TIMING OF BRAKE LINING

Remove the rubber plugs from the check holes, and inspect the
wear status of the lining. If the brake lining is worn to the stepped
point, replace it. There are two check holes per wheel. Be sure to
inspect at both check holes.
<Wedge type>
To install the brake shoe, check the pivot plate’s shape for adjusting
the shoe clearance.
If the cast shoe pivot plate has been removed, install it after coating
the bolt thread with Loctite #241 (or equivalent).
BR-44
BRAKE CHAMBER FRONT
BRAKE CHAMBER FRONT

CONSTRUCTION
Type I, II
Type III, IV (Internal release type: with spring chamber)
BR-45
BRAKE CHAMBER FRONT
Type V (Internal release type : with spring chamber)
REMOVAL AND INSTALLATION

Key point of removal
<Type III, IV, V : Internal release type>
1. Release the parking brake, and manually release the mechan-
ical release bolt by turning it leftward (counterclockwise), while
applying air to the chamber assembly’s spring brake side. Turn
the mechanical release bolt up to the position where the revo-
lution torque suddenly increases, and tighten it with 45 N•m
{4.6 kgf•m}.
CAUTION
 When tightening, do not use an impact wrench because
it may damage the chamber assembly.
 When starting the manual release, the indicator pin
which is in the center of the release bolt gradually
sticks out in the first several rotation by approximately
5 mm, but this is not the indicator which indicates the
completion of the release. Be careful not to break the
indicator pin.
2. Activate the parking brake to discharge air to the chamber
assembly, and remove the chamber assembly from the vehi-
cle.
NOTE
 Make sure that the chamber assembly’s indicator pin is
sticking out.
BR-46
BRAKE CHAMBER FRONT
Key point of installation

<Type III, IV, V: Internal release type>
1. Install the chamber assembly to the vehicle in the reverse
sequence of the removal.
NOTE
 Make sure that the chamber assembly’s indicator pin is
sticking out.
2. Release the parking brake and turn the mechanical release
bolt rightward (clockwise), while applying air to the chamber
assembly's spring brake side, to have the normal condition.
Turn the mechanical release bolt until the indicator located at
the center of the release bolt completely retreats as shown in
the figure right as a normal condition, then tighten it with 45
N•m {4.6 kgf•m}.
CAUTION
it may damage the chamber assembly.
 Before running the vehicle, make sure to reconfirm that
the indicator is in the normal condition as shown in the
figure right.
BR-47
BRAKE CHAMBER FRONT

Type I, II

1 Nut 2 Clamp band bolt 3 Clamp band
4 Diaphragm 5 Cap 6 Chamber bracket
7 Stem 8 Retaining ring 9 Plate
10 Radial oil seal 11 Guide 12 O-ring
13 Guide ring 14 Tolerance ring 15 Washer
16 Push rod assembly 17 Plug
BR-48
BRAKE CHAMBER FRONT
Type III, IV (Internal release type: with spring chamber)

1 Hose 2 Filter 3 Nut
4 Clamp band bolt 5 Clamp band 6 Diaphragm
7 Spring cylinder sub assembly 8 Chamber bracket 9 Push rod assembly
10 Retaining ring 11 Plate 12 Radial oil seal
13 Stem 14 Guide ring 15 Tolerance ring
16 Washer 17 Guide 18 O-ring
19 Plug 20 Hose stud
BR-49
BRAKE CHAMBER FRONT
Type V (Internal release type : with spring chamber)
isassembly sequence (assembly is done in the reverse sequence of disassembly)

4 Diaphragm 5 Spring cylinder sub assembly 6 Chamber bracket
7 Push rod assembly 8 Retaining ring 9 Plate
10 Radial oil seal 11 Stem 12 Guide ring
13 Tolerance ring 14 Washer 15 Guide
16 O-ring
BR-50
BRAKE CHAMBER FRONT

<Type I, II>
1. Mark matching marks on the clamp ring cylinder sub assem-
bly, the clamp band and the chamber bracket.
2. Horizontally place the chamber assembly on a flat table, and
put marks on the chamber bracket or the cap to show the
insertion direction of the clamp band bolt.
Remove the nut and the clamp band bolt, then the clamp
band. When doing this, be careful not to roll the chamber.
CAUTION
 Do not fix the chamber assembly by holding it with a
vise, etc. Doing so may deform the chamber. When
removing the clamp band, do not open the inlet of the
clamp band's bolt for 80 mm or more.
3. Place the chamber bracket having the clamp band installation

side facing up. While holding it with one hand, hold the push
rod assembly’s push rod plate with the other hand. At the posi-
tion it hits the inside, let it hit it several times and pull it out
straight.
CAUTION
 Be very careful not to damage the push rod assembly’s
push rod. Do not shake the push rod assembly up and
down or left and right, or do not hit it from the square
flange side.
4. Remove the stem, take out the retaining ring from the chamber
bracket, and remove the plate and the radial oil seal.
CAUTION
 Wear protective glasses in case the retaining ring
springs out.
5. With the chamber bracket’s square flange side kept upside,
slightly hit one side of the guide with a bar and a plastic ham-
mer the outside diameter of which is approximately 8 to 10
mm to rotate the guide 90°. Then, push the guide out by
slightly hitting it with a cylinder and a plastic hammer of
approximately 36 mm.
CAUTION
 Be very careful not to damage the paint inside the
chamber bracket.
BR-51
BRAKE CHAMBER FRONT
6. Remove the guide ring from the stem, and remove the toler-
ance ring (in some cases, the tolerance ring is contained in the
tip of the push rod assembly. In this case, take it out with a
driver, etc.).
NOTE
 Keep aside the washer installed in the stem (NOTE that it
is not always installed in the stem) because it is used
when assembling.

1. Mark matching marks on the spring cylinder sub assembly, the
clamp band and the chamber bracket.
2. Horizontally put the chamber assembly on a flat table and
mark the chamber bracket or the spring cylinder sub assembly
with a mark which shows the insert direction of the clamp band
bolt. Remove the nut and clamp band, then remove the clamp
CAUTION
removing the clamp band, do not open the bolt inlet of
the clamp band for 80 mm or more.
BR-52
BRAKE CHAMBER FRONT

straight.
CAUTION
flange side.
CAUTION
springs out.
CAUTION
chamber bracket.
BR-53
BRAKE CHAMBER FRONT
driver, etc.).
NOTE
when assembling.
7. Insert a bar or a screw driver of 6 to 8 mm from hose stud’s
hose inlet side, and slightly hit the plug with a plastic hammer
and remove it from the chamber bracket. Then, remove the
hose stud.

<Type I, II>
1. Coat the chamber bracket with the grease which is specified to
be used and included in the repair kit.
NOTE
 Be careful not to forget to apply the grease or not to
apply the grease excessively.
 Appropriate grease amount: Approximately 1 - 1.5g.
 Do not use grease other than the one which is specified
to be used and included in the repair kit.
2. Coat a new O-ring with the grease and install it to a new guide.
Bring the guide’s bead side to the diaphragm side, and insert it
straight with fingers until it hits the chamber bracket. Then,
first, install a new radial oil seal, and next, a new plate (3 mm
thick), and fix them with a new retaining ring. When fixing them
with a retaining ring, insert the retaining ring into the groove by
pushing the plate with a 22 mm box socket or by pushing the
retaining ring with a 27 mm box socket. When assembling,
make sure again that each installation direction and the
sequence of the installation are as per the figure below.
CAUTION
 Make sure again that there are no scratches or foreign
materials sticking to the chamber bracket’s area insert-
ing the guide and O-ring or seal surface.
 Make sure that there are no scratches or streaks of hit-
ting on the new guide’s bead area.
 Be careful with the guide’s insertion direction. If it is
inserted wrong way, do not reuse the O-ring and the
guide.
 Make sure that a ring-shaped spring is attached to the
new radial oil seal.
 Make sure that the retaining ring is securely inserted
into the groove.
BR-54
BRAKE CHAMBER FRONT
3. Coat the push rod assembly’s push rod with specified grease
and insert it into the inside diameter without damaging the
radial oil seal.
4. Mount a new diaphragm and a cap on the sub assembly
assembled in the foregoing step 3 and match the matching
marks. When doing this, install the diaphragm at the center so
that the inscribed letters WABCO come to the cap side. Make
sure that the diaphragm’s outside diameter is almost the same
as the flange’s outside diameter.
NOTE
 Make sure that the maker and the size of the new dia-
phragm for replacement are the same as those of the old
diaphragm when disassembled.
 Do not use diaphragms other than those specified to be
used and included in the repair kit.
5. Hang the clamp band matching the matching marks. Gradually
hold the band’s bolt inlet holes together with a vise and tighten
them until the distance between the bolt inlet holes becomes
approximately 15 to 20 mm. Then, remove the vise and tem-
porarily fix it with the clamp band bolt and nut. (pay attention to
the inserting direction of the band bolt)
Then, slightly hit the entire out-of-roundness of the clamp band
with a plastic hammer and tighten the nut. Repeat this 2 to 3
times and gradually tighten the nut.
6. Horizontally put the chamber assembly on a flat table, and

apply 700 to 800 kPa {7 to 8 kgf/cm2} air pressure to the port.
7. Install a new guide ring to the stem.
NOTE
 When doing this, do not install the tolerance ring.
8. Put the stem into the chamber bracket with the set gauge as a
tool (99862 Z0001).
NOTE
 Insert the stem until it hits the push rod’s hole.
BR-55
BRAKE CHAMBER FRONT
9. While keeping the set gauge as a tool pressed to the stem,

heap washers in the dent for washer adjustment located on
the set gauge’s edge.
10. Decide the maximum number of washers which hangs to the
inside diameter of the chamber bracket when the top washer
of the heap is slid outward (the washer disassembled can be
used).
CAUTION
 The number of washers decided here must be correctly
stored because it becomes the number for adjusting the
set size of the stem. Be careful if the number of washers
decided in this procedure is mistaken, disassembly may
become necessary again.
NOTE
 The number of washers, reference: Approximately 0 - 4
washers
 Thickness (1 washer): 0.5 mm
11. Take out the set gauge as a tool and the stem. Install the
washers the number of which has been determined in the fore-
going step 10 and a new tolerance ring to the stem, and push
the stem again with the set gauge as a tool until it hits the hole.
When doing this, lay the assembly so that the washers do not
drop.
CAUTION
 After the installation, while keeping the set gauge as a
tool pressed to the stem, make sure that the edge of the
chamber bracket side is almost on the same level as the
level for checking the set size of the set gauge.
12. After the work completed, discharge air from the port.
BR-56
BRAKE CHAMBER FRONT

1. Install a new hose stud to the chamber bracket. When doing
this, set the hose stud so that it faces the diaphragm side.
Insert the plug from the tip of the hose stud. Put in the bar or
driver (+) used when disassembling, and slightly hit it with a
plastic hammer so that the plug’s tip almost concur with the
hose stud’s tip.
CAUTION
 Make sure that the plug’s direction and its installation
state are as per the following figure. When inserting a
bar or a driver, be careful that its tip does not damage
the hose stud.
 After installing the plug, make sure that the hose stud is
not removed by the force of 60 N {6.1 kgf}.

NOTE
 Appropriate Grease amount: Approximately 1 - 1.5g.
BR-57
BRAKE CHAMBER FRONT
CAUTION
materials sticking to the bracket’s guide inserting area,
O-ring or seal surface.
guide.
into the groove.
and insert it into the radial oil seal’s inside diameter without
damaging it.
that the inscribed letters WABCO come to the spring cylinder
sub assembly side. Make sure that the diaphragm’s outside
diameter is almost the same as the flange’s outside diameter.
NOTE
diaphragm disassembled.
 When changing to a new spring cylinder sub assembly,
make sure to put matching marks on the same position
as the spring cylinder sub assembly disassembled.
BR-58
BRAKE CHAMBER FRONT

hold the band’s bolt inlet holes together with a vise or similar
device and tighten them until the distance between the bolt inlet
holes becomes approximately 15 to 20 mm. Then, remove the
vise and temporarily fix it with the clamp band bolt and nut. (pay
attention to the inserting direction of the band bolt)

apply 700 to 800 kPa {7 to 8 kgf/cm2} air pressure to the port A
(spring brake side).
NOTE
tool (99862 Z0001).
NOTE
used).
CAUTION
NOTE
washers
12. Take out the set gauge as a tool and the stem. Install the wash-
ers the number of which has been determined in the foregoing
step 11 and a new tolerance ring to the stem, and push the stem
again with the set gauge as a tool until it hits the hole. When
doing this, lay the assembly so that the washers do not drop.
BR-59
BRAKE CHAMBER FRONT
CAUTION
13. After the work completed, discharge air from the port A (spring
brake side).
14. Insert a new filter into the tip of the hose (smaller diameter side
becomes the hose side), and insert it into the hose stud until
the swell of the hose comes to the center of stud’s hill.
CAUTION
 When inserting the hose into the hose stud, do not coat
it with oil such as grease.
NOTE
 The filter is installed only to the chamber bracket side.
There is no filter on the spring cylinder sub assembly
side.
BR-60
BRAKE CHAMBER FRONT
INSPECTION
Clean all disassembled parts in cleaning solvent. Check carefully
for scratches, cracks, etc. Replace faulty parts with new ones.
CAP (TYPE I, II)

There are no scratches or streaks of hitting on the diaphragm seal.
SPRING CYLINDER SUB ASSEMBLY (TYPE III, IV, V :

INTERNAL RELEASE TYPE)
 There are no dents on the cylinder. There are no scratches or
streaks of hitting on the diaphragm seal.
 This sub assembly should be replaced every 3 years.
HOSE (TYPE III, IV : INTERNAL RELEASE TYPE)

There are no scratches, bending, etc.
CLAMP BAND
There is no significant deformation. If there is deformation or break-
age (including rust), replace it (recommendation: Replace every 3
years).
CLAMP BAND BOLT, NUT

There are no crush of the thread, bending of the bolt, and rust.
PUSH ROD ASSEMBLY

 There are no scratches, streaks of hitting, rust of the plate on
the push rod and the push rod plate.
 The push plate does not rotate.
NOTE
 The push rod assembly cannot be disassembled, so
replace it as an assembly.
STEM
There are no scratches, hitting streaks on the dent and the push
rod inserting area (10 mm area).
CHAMBER BRACKET
 There are no scratches or hitting streaks on the diaphragm
seal.
 There are no scratches on the stem’s sliding area.
 There are no scratches on the guide inserting area, O-ring,
seal surface.
 There are no breakage, cracks or deformation on the flange
installed.
 There are no other breakage, cracks, or deformation on the
appearance.
 There are no scratches on the O-ring, seal surface of the other
side.
BR-61
BRAKE CHAMBER FRONT
AIR LEAKAGE INSPECTION

After assembly, check the leakage of air with the following method.
<Type I, II>
When air pressure 700 to 800 kPa {7 to 8 kgf/cm2} is applied to the
port, the leakage at each part must be 8 cm3 /min or less in total.
CAUTION
 When checking this, be careful because the stem in the
chamber bracket strokes.
1. When air pressure 700 to 800 kPa {7 to 8 kgf/cm2} is applied
to the port A (spring brake side), the leakage at each part must
be 8 cm3 /min or less in total.
NOTE
 When doing this, also check the leakage at the port B
(service brake side).
to the port B (service brake side), the leakage at each part
must be 8 cm3 /min or less in total.
CAUTION
BR-62
BRAKE CHAMBER REAR
BRAKE CHAMBER REAR

CONSTRUCTION
Type I
Type II (Standard type: with spring chamber) <except for dump, mixer model>
BR-63
BRAKE CHAMBER REAR
Type III (IBV type: with spring chamber) <dump, mixer model>
Type IV (Camshaft type)
BR-64
BRAKE CHAMBER REAR
Type V (Camshaft type)
REMOVAL AND INSTALLATION

Key point of removal
<Type II, III, V : Standard type and IBV type>
1. Release the parking brake. While applying air to the spring
brake side of the chamber assembly, turn the mechanical
release bolt counter clock wise to manually release it and
tighten it with 15 N•m {1.5 kgf•m}.
CAUTION
it may break the chamber assembly.
2. Activate the parking brake, and after discharging air to the

chamber assembly, remove the chamber assembly from the
vehicle.
NOTE
 Make sure again that the mechanical release bolt of the
chamber assembly is sticking out.
BR-65
BRAKE CHAMBER REAR
Key point of installation

1. Install the chamber assembly to the vehicle in the reverse
sequence of the removal.
NOTE
 Make sure that the mechanical release bolt of the cham-
ber assembly is sticking out.
2. Release the parking brake. While applying air to the spring

brake side of the chamber assembly, turn the mechanical
release bolt rightward (clockwise) to return to the normal state
and tighten it with 25 to 45 N•m {2.5 to 4.6 kgf•m}.
CAUTION
it may break the chamber assembly.
BR-66
BRAKE CHAMBER REAR

Type I

1 Nut 2 Clamp bolt 3 Clamp band
4 Diaphragm 5 Cap 6 Chamber bracket
7 Stem 8 Retaining ring 9 Plate
10 Radial oil seal 11 Guide 12 O-ring
13 Guide ring 14 Tolerance ring 15 Washer
16 Push rod assembly 17 Plug
BR-67
BRAKE CHAMBER REAR
Type II (Standard type: with spring chamber) <except for dump, mixer>

1 Hose 2 Filter 3 Nut
4 Clamp band bolt 5 Clamp band 6 Diaphragm
7 Spring cylinder sub assembly 8 Chamber bracket 9 Push rod assembly
10 Retaining ring 11 Plate 12 Radial oil seal
13 Stem 14 Guide ring 15 Tolerance ring
16 Washer 17 Guide 18 O-ring
19 Plug 20 Hose stud
BR-68
BRAKE CHAMBER REAR
Type III (IBV type: with spring chamber) <dump, mixer model>

4 Diaphragm 5 Spring cylinder sub assembly 6 Chamber bracket
7 Push rod assembly 8 Retaining ring 9 Plate
10 Radial oil seal 11 Stem 12 Guide ring
13 Tolerance ring 14 Washer 15 Guide
16 O-ring
BR-69
BRAKE CHAMBER REAR
isassembly sequence (Assembly is done in the reverse sequence of disassembly)

1 Clamp band 2 Pressure plate 3 Diaphragm
4 Push rod 5 Return spring 6 Non-pressure plate
BR-70
BRAKE CHAMBER REAR
Parts name
1 Spring cylinder sub assembly 2 Diaphragm 3 Push rod assembly
4 Cap 5 Spring 6 Flange
7 Plain washer 8 Clamp band 9 Clamp band bolt
10 Nut 11 Chamber bracket
BR-71
BRAKE CHAMBER REAR

<Type I>
1. Mark matching marks on the clamp ring cylinder sub assem-
bly, the clamp band and the chamber bracket.
2. Horizontally place the chamber assembly on a flat table, and
put marks on the chamber bracket or the cap to show the
insertion direction of the clamp band bolt. Remove the nut and
the clamp band bolt, then the clamp band. When doing this, be
careful not to roll the chamber.
CAUTION
removing the clamp band, do not open the inlet of the
clamp band’s bolt for 80 mm or more.
straight.
CAUTION
flange side.
CAUTION
springs out.
CAUTION
chamber bracket.
BR-72
BRAKE CHAMBER REAR
driver, etc.).
NOTE
when assembling.
<Type II, III: Standard type and IBV type>

1. Mark matching marks on the spring cylinder sub assembly, the
clamp band and the chamber bracket.
2. Horizontally put the chamber assembly on a flat table and
mark the chamber bracket or the spring cylinder sub assembly
with a mark which shows the insert direction of the clamp band
bolt. Remove the nut and clamp band, then remove the clamp
CAUTION
removing the clamp band, do not open the bolt inlet of
the clamp band for 80 mm or more.
straight.
BR-73
BRAKE CHAMBER REAR
CAUTION
flange side.
CAUTION
springs out.
CAUTION
chamber bracket.
driver, etc.).
NOTE
when assembling.
BR-74
BRAKE CHAMBER REAR
7. Insert a bar or a screw driver of 6 to 8 mm from hose stud’s

hose inlet side, and slightly hit the plug with a plastic hammer
and remove it from the chamber bracket. Then, remove the
hose stud.
<Type IV (Camshaft type)>

1. Put matching marks on the pressure plate, non-pressure plate,
and clamp band.
2. The pressure plate is pushed up by the spring force of the

return spring. Remove the clamp band while pressing the
pressure plate against the spring force.
<Type V (Camshaft type)>

1. Apply match marks to the spring cylinder sub-assembly, the
clamp band, and the chamber bracket.
2. Secure the chamber assembly on a work bench with the
mechanical release bolt facing downwards, and using a press
or the like, gently press the chamber assembly side to secure
it.
CAUTION
 The chamber assembly may be broken if excessive
force is applied using a press or the like, and appropri-
ate care should be taken.
3. Apply a mark to the chamber bracket or the spring cylinder sub

assembly in order to clearly indicate the clamp band insertion
direction, and following this, remove the band’s nut and bolt,
following by the clamp band itself.
CAUTION
 When removing the clamp band, take care to avoid
opening its bolt insertion section (i.e., Dimension A) by
80 mm or more.
4. Slowly reduce the force applied by the press and remove it.
The spring cylinder sub assembly, diaphragm, push rod
assembly, cap, spring, flange, plain washer, and chamber
bracket will come apart.
BR-75
BRAKE CHAMBER REAR
CAUTION
 Do not release the press force all at once. To prevent
the chamber bracket to spring up or topple over, hold
down the chamber bracket manually while loosening
the press force.

<Type I>
NOTE
CAUTION
materials sticking to the chamber bracket’s area insert-
ing the guide and O-ring or seal surface.
guide.
into the groove.
BR-76
BRAKE CHAMBER REAR
and insert it into the inside diameter without damaging the
radial oil seal.
that the inscribed letters WABCO come to the cap side. Make
sure that the diaphragm’s outside diameter is almost the same
as the flange’s outside diameter.
NOTE
diaphragm when disassembled.
hold the band's bolt inlet holes together with a vise and tighten
them until the distance between the bolt inlet holes becomes
approximately 15 to 20 mm. Then, remove the vise and tem-
porarily fix it with the clamp band bolt and nut. (pay attention to
the inserting direction of the band bolt)

apply 700 to 800 kPa {7 to 8 kgf/cm2} air pressure to the port.
NOTE
tool (99862 Z0001).
NOTE
BR-77
BRAKE CHAMBER REAR

used).
CAUTION
NOTE
washers
drop.
CAUTION
12. After the work completed, discharge air from the port.
BR-78
BRAKE CHAMBER REAR
<Type II: Standard type (except for dump, mixer

model)>
1. Install a new hose stud to the chamber bracket. When doing
this, set the hose stud so that it faces the diaphragm side.
Insert the plug from the tip of the hose stud. Put in the bar or
driver (+) used when disassembling, and slightly hit it with a
plastic hammer so that the plug’s tip almost concur with the
hose stud’s tip.
CAUTION
 Make sure that the plug’s direction and its installation
state are as per the following figure. When inserting a
bar or a driver, be careful that its tip does not damage
the hose stud.
 After installing the plug, make sure that the hose stud is
not removed by the force of 60 N {6.1 kgf}.

NOTE
BR-79
BRAKE CHAMBER REAR
CAUTION
guide.
into the groove.
and insert it into the radial oil seal’s is inside diameter without
damaging it.

NOTE
BR-80
BRAKE CHAMBER REAR

device and tighten them until the distance between the bolt
inlet holes becomes approximately 15 to 20 mm. Then,
remove the vise and temporarily fix it with the clamp band bolt
and nut. (pay attention to the inserting direction of the band
bolt)

NOTE
tool (99862 Z0001).
NOTE
used).
CAUTION
NOTE
washers
BR-81
BRAKE CHAMBER REAR
drop.
CAUTION
brake side).
14. Insert a new filter into the tip of the hose (smaller diameter side
becomes the hose side), and insert it into the hose stud until
the swell of the hose comes to the center of stud’s hill.
CAUTION
 When inserting the hose into the hose stud, do not coat
it with oil such as grease.
NOTE
 The filter is installed only to the chamber bracket side.
There is no filter on the spring cylinder sub assembly
side.
BR-82
BRAKE CHAMBER REAR
<Type III: IBV type (dump, mixer model)>

NOTE
CAUTION
guide.
into the groove.
BR-83
BRAKE CHAMBER REAR
and insert it into the radial oil seal’s inside diameter without
damaging it.
NOTE
BR-84
BRAKE CHAMBER REAR

device and tighten them until the distance between the bolt
inlet holes becomes approximately 15 to 20 mm. Then,
remove the vise and temporarily fix it with the clamp band bolt
and nut (pay attention to the inserting direction of the band
bolt).

NOTE
tool (99862 Z0001).
NOTE
used).
CAUTION
NOTE
washers.
 Thickness (1 washer): 0.5 mm.
BR-85
BRAKE CHAMBER REAR
drop.
CAUTION
brake side).

1. Assemble the pressure plate to the non-pressure plate by
aligning the match marks.
2. Install the clamp band while tapping the outer periphery of the
band with a plastic hammer.
3. Attach the lock nut and clevis to the push rod, and adjust
dimension L. Tighten the lock nut.
BR-86
BRAKE CHAMBER REAR

1. Ensure that the cap is oriented as shown in the following figure
when putting together the push rod assembly.
2. Mount the spring on the sub-asse,bly from step 1 in order to
complete the push rod sub assembly.
CAUTION
 When assembling the spring on the sub-assembly,
ensure that the end with the smaller coil diameter is
closest to the cap.
3. Assemble the flange and then the plain washer onto the push
rod sub assembly from step 2.
CAUTION
 Ensure that the flange is oriented as shown in the figure
with the outer spring coil fitting into its rim.
4. Secure the spring cylinder sub assembly on a workbench with

the mechanical release bolt facing downward; assemble a new
diaphragm, the push rod sub assembly from step 3, and the
chamber bracket; and then apply gentle force with a press or
the like so as to bring the match marks into alignment. At this
time, ensure that the diaphragm is installed in such a way that
the raised letters (WABCO) face the spring cylinder sub
assembly; furthermore, in order to ensure that the diaphragm
is centered, its outer diameter and that of the spring cylinder
sub assmbly should be essentially identical.
BR-87
BRAKE CHAMBER REAR
CAUTION
 In order to prevent the end face of the flange from sit-
ting on top of the stud-bolt welded section when posi-
tioning the chamber bracket or applying force with a
press, carefully place the flange inside the inner edges
of the chamber sub assembly.
 Ensure that the manufacturer name (WABCO in raised
letters) and size of the new replacement diaphragm are
identical to those of the old removed part. Under no cir-
cumstances should any othher type of diaphragm be
used.
5. Assemble the clamp band with its match mark aligned and
tighten its bolt and nut to finger tightness. (Special care should
be taken to insert the clamp band bolt in the right direction.)
Following this, lightly tap the entire outer circumference of the
clamp band with a plastic hammer and then tighten the nut in
two or three stages.
BR-88
BRAKE CHAMBER REAR
INSPECTION
CAP (TYPE I), PRESSURE PLATE (TYPE IV)

There are no scratches or streaks of hitting on the diaphragm seal.
SPRING CYLINDER SUB ASSEMBLY (TYPE II, TYPE III

AND TYPE V)
 There are no dents on the cylinder. There are no scratches or
streaks of hitting on the diaphragm seal.
 This sub assembly should be replaced every 3 years.
HOSE (TYPE II)

There are no scratches, bending, etc.
CLAMP BAND
There is no significant deformation. If there is deformation or break-
age (including rust), replace it (recommendation: Replace every 3
years).
CLAMP BAND BOLT, NUT

There is no crush of the thread, bending of the bolt, and rust.
PUSH ROD ASSEMBLY

 There are no scratches, streaks of hitting, rust of the plate on
the push rod and the push plate.
 The push plate does not rotate.
NOTE
 The push rod assembly cannot be disassembled, so
replace it as an assembly.
STEM
There are no scratches, hitting streaks on the dent and the push
rod inserting area (10 mm area).
CHAMBER BRACKET
 There are no scratches or hitting streaks on the diaphragm
seal.
 There are no scratches on the stem’s sliding area.
 There are no scratches on the guide inserting area, O-ring,
seal surface.
 There are no breakage, cracks or deformation on the flange
installed.
 There are no other breakage, cracks, or deformation on the
appearance.
 There are no scratches on the O-ring, seal surface of the other
side.
BR-89
BRAKE CHAMBER REAR
AIR LEAKAGE INSPECTION

After assembly, check the leakage of air with the following method.
<Type I and Type IV>
When air pressure 700 to 800 kPa {7 to 8 kgf/cm2} is applied to the
port, the leakage at each part must be 8 cm3 /min or less in total.
CAUTION
<Type II, Type III and Type V>

to the port A (spring brake side), the leakage at each part must
be 8 cm3 /min or less in total.
NOTE
 When doing this, also check the leakage at the port B
(service brake side).
to the port B (service brake side), the leakage at each part
must be 8 cm3 /min or less in total.
CAUTION
BR-90
SERVICE DATA
SERVICE DATA
SPECIFICATIONS
<Front>
Unit: mm
Vehicle type CWB GWB GKB
Unit nominal BAL41
Brake shoe type Leading trailing
Brake drum inside diameter 410
Brake lining size (width thickness) 180 16
Chamber size #22 #24 #24
<Rear>
Unit: mm
CWB
Vehicle type GWB GKB
Wedge type Camshaft type
Front BPL41
Unit Nominal
Rear BPL41 –
Front Leading trailing
Brake shoe type
Rear Leading trailing –
Front 410
Brake drum inside diameter
Rear 410 –
Front 220  16
Brake lining size (width thickness)
Rear 220  16 –
Front #24 #30 #24
Chamber size
Rear #24 #24 #24 –
UNIT NAME
BR-91
SERVICE DATA
APPLICATION
R.H.D. model
CWB series
O mark indicates that the application is possible.
CWB CWB-P (Full trailer)
Vehicle type Leaf suspension
With ABS With ABS With ABS/ASR With EBS
Front BAL41
Brake main unit
Rear BPL41
Standard model O O O –
Brake valve
EBS model – – – O
Parking brake valve O O O O
Air pressure governor One unit type with air dryer
Air dryer O O O O
Oil mist separator O O O O
Air dryer inlet O O O O
Supply tank inlet One unit type with air dryer
Check valve Auxiliary tank inlet O O O O
Spring brake tank inlet – – – –
Spring brake tank outlet – – – O
Multi-protection valve One unit type with air dryer
For trailer – O O O
Pressure
For auxiliary One unit type with air dryer
reducing valve
For auxiliary from supply tank – – – O
L.Q.R.V. (Limiting quick release valve) – O (Optional) O (Optional) O (Optional)
Pressure protec- For trailer – O O –
tion valve For auxiliary from supply tank – – – O
Safety valve O O O O
For primary O O O –
Relay valve For secondary O O O –
For wheel park O O O O
Proportional relay valve – – – O
Double check valve O O O O
Trailer control valve – O O O
Trailer hand brake valve – O O –
BR-92
SERVICE DATA
GKB tractor
GKB
Vehicle type Leaf suspension Air suspension
With ABS With ABS/ASR With EBS With EBS
Front BAL41
Brake main unit
Rear BPL41
Standard model O O – –
Brake valve
EBS model – – O O
Air pressure Standard pressure
One unit type with air dryer
governor specifications
Air dryer O O O O
Check valve
Spring brake tank inlet O O – –
Spring brake tank outlet – – O O
Pressure For trailer O O O O
reducing valve For auxiliary One unit type with air dryer
L.Q.R.V. (Limiting quick release valve) O (Optional) O (Optional) O (Optional) O (Optional)
For trailer O O – –
Pressure protec-
tion valve For auxiliary from supply
– – – O
tank
Safety valve For supply tank O O O O
For primary O O – –
Relay valve For secondary O O – –
Proportional relay valve – – O O
Trailer control valve O O O O
Trailer hand brake valve O O – –
BR-93
SERVICE DATA
GWB tractor
GWB
Vehicle type Leaf suspension Air suspension
With ABS With ABS/ASR With EBS With EBS
Front BAL41
Brake main unit
Rear BPL41
Standard model O O – –
Brake valve
EBS model – – O O
Air pressure Standard pressure
One unit type with air dryer
governor specifications
Air dryer O O O O
Check valve
Spring brake tank inlet O O – –
Spring brake tank outlet – – O O
For trailer O O O O
Pressure reduc- For auxiliary One unit type with air dryer
ing valve For auxiliary from supply
– – O O
tank
L.Q.R.V. (Limiting quick release valve) O (Optional) O (Optional) O (Optional) O (Optional)
For trailer O O – –
Pressure protec-
tion valve For auxiliary from supply
– – O O
tank
Safety valve For supply tank O O O O
For primary O O – –
Relay valve For secondary O O – –
Proportional relay valve – – O O
Trailer control valve O O O O
Trailer hand brake valve O O – –
BR-94
SERVICE DATA
L.H.D. model
CWB CWB (Full trailer) GKB GWB
Leaf suspension
Vehicle type
With With With
With ABS With ABS With ABS With ABS
ABS/ASR ABS/ASR ABS/ASR
Brake main Front BAL41
unit Rear BPL41
Brake valve Standard model O O O O O O O
Parking brake valve O O O O O O O
Air pres-
Standard pressure
sure gover- One unit type with air dryer
specifications
nor
Air dryer O O O O O O O
Oil mist separator O O O O O O O
Air dryer inlet O O O O O O O
Check
valve Auxiliary tank inlet O O O – – – –
Spring brake tank
– – – O O O O
inlet
Pressure For trailer – O O O O O O
reducing
valve For auxiliary One unit type with air dryer
L.Q.R.V. O O O O O O
–
(Limiting quick relay valve) (Optional) (Optional) (Optional) (Optional) (Optional) (Optional)
Pressure protection valve – O O O O O O
Safety
For supply tank O O O O O O O
valve
For primary O O O O O O O
Relay
For secondary O O O O O O O
valve
For wheel park O O O O O O O
Double check valve O O O O O O O
Trailer con- Standard
– O O O O O O
trol valve specification
Trailer hand brake valve – O O O O O O
BR-95
SERVICE DATA
OUTLINE OF BRAKE SYSTEM

CWB (ABS) <cargo for South Africa>
BR-96
SERVICE DATA
CWB (ABS) <dump for South Africa>
BR-97
SERVICE DATA
CWB (ABS) <dump (camshaft type) for South Africa>
BR-98
SERVICE DATA
CWB-P (EBS) <Full trailer for South Africa>
BR-99
SERVICE DATA
GKB (EBS) <South Africa>
BR-100
SERVICE DATA
GWB (EBS) <South Africa>
BR-101
SERVICE DATA
CWB (ABS) <cargo>
BR-102
SERVICE DATA
CWB (ABS) <dump, mixer>
BR-103
SERVICE DATA
CWB (ABS) <dump, mixer (camshaft type)>
BR-104
SERVICE DATA
CWB-P (ABS, ABS/ASR) <Full trailer>
BR-105
SERVICE DATA
GKB (ABS, ABS/ASR)
BR-106
SERVICE DATA
GWB (ABS, ABS/ASR)
BR-107
SERVICE DATA
SERVICE DATA
Unit: mm
Maintenance Service
Item Remarks
standard limit
Front wheel 410 414
Inside diameter
Brake drum Rear wheel 410 414
Thickness of brake Front wheel 16 5
lining Rear wheel 16 5
Front whee 34.90 - 34.94 34.85
Anchor pin outside
Wedge type 34.90 - 34.94 34.85
diameter Rear wheel
Camshaft type 29.895 - 29.93 29.85
Front whee 35.00 - 35.05 35.15
Brake shoe bushing
Wedge type 35.00 - 35.05 35.15
inside diameter Rear wheel
Camshaft type 30.00 - 30.05 30.15
Clearance between anchor pin Wedge type 0.06 - 0.15 0.30
Brake shoe
and brake shoe bushing Camshaft type 0.07 - 0.20 0.25
Brake shoe roller inside
diameter
Brake shoe roller outside
diameter
Brake shoe roller pin
outside diameter
Clearance between brake
shoe roller and brake shoe Camshaft type 0.20 - 0.43 0.80
roller pin
Camshaft bushing inside
diameter
Camshaft Camshaft outside diameter Camshaft type 40.0 39.7
Clearance between camshaft
bushing and camshaft
Free length 203.7 –
Front return When spring
spring 593 - 724
Tension [N {kgf}] – length is 229.5
{60.5 - 73.8}
mm
BR-108
SERVICE DATA
Maintenance Service
Item Remarks
standard limit
Wedge type 200.8 –
Free Cam- Outer 195.3 –
Rear front
length shaft Inner 242.6 –
type Rear rear 186.7 –
When spring
541.6 - 635.6
Wedge type – length is 230.0
{55.24 - 64.83}
mm
Rear return
When spring
spring 549 - 637
Outer – length is 219.0
{56.0 - 65.0}
mm
Tension Rear front
Cam- When spring
198 - 233
shaft Inner – length is 252.5
{20.2 - 23.8}
type mm
When spring
701 - 809
Rear rear – length is 219.0
{71.5 - 82.5}
mm
EXPANDER
Item Maintenance standard Service limit Remarks
Clip holding torque of adjust screw assembly
1.5 - 5.0 {0.15 - 0.5} –
[N•m {kgf•m}]
Rotation torque of sleeve assembly
[N•m {kgf•m}] Counterclockwise rev-
2.0 {0.2} or more –
olution
Spring tension When installation
78.5 {8.0} 73.6 {7.5} or less
[N {kgf}] length is 11.3 mm
Wedge spring tension When installation
147 {15.0} 132.3 {13.3} or less
[N {kgf}] length is 105.8 mm
38.1 - 38.2 –
[mm]
BR-109
SERVICE DATA
TIGHTENING TORQUE
Tightening torque
Item Remarks
N•m kgf•m
Expander mounting bolt 14.1 - 23.9 1.4 - 2.4
Set screw of sleeve assembly (expander) 12 - 18 1.2 - 1.8
Brake chamber mounting bolt 36.2 - 51.8 3.7 - 5.3
Front 45 4.6
Mechanical release bolt When manually released 15 1.5
Rear
When normally released 25 - 45 2.5 - 4.6
Dust cover mounting bolt 20.1 - 33.9 2.05 - 3.46
Anchor pin set screw 20.1 - 33.9 2.05 - 3.46
Wedge type and spring
Brake chamber clamp mounting 25 - 30 2.5 - 3.0
brake chamber
bolt nut
Rear STD camshaft type 19.6 - 25.4 2.0 - 2.6 BPL41
Wheel speed sensor bracket 59 - 109 6.0 - 11.1 BAL41
Wheel speed sensor bracket mounting bolt 15.7 - 20.6 1.6 - 2.1 BPL41
Wheel speed sensor clamp mounting bolt 4.0 - 5.8 0.4 - 0.6 BPL41
Brake chamber bracket mounting
Camshaft type 137.2 - 156.8 14.0 - 16.0 BPL41
bolt
Brake chamber mounting nut Camshaft type 167.2 - 186.8 17.0 - 19.0 BPL41
Brake bracket mounting bolt or nut 216 - 294 22.0 - 30.0
BR-110

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BRAKE SYSTEM

Used to replace the lining or remove the shoe assem-

Cage setter (Replacer)

Boot setter (Replacer)

Adapter Used to measure the expander’s clip retaining torque

Used to removal/install return spring

BRAKE ASSEMBLY BAL41 TYPE

DISASSEMBLY AND REASSEMBLY

Disassembly sequence (Reassembly Sequence is in the reverse order of disassembly.)

Disassembly sequence (Reassembly Sequence is in the reverse order of disassembly.)

Key point of disassembly

2. Remove the boot by inserting a flat-blade screwdriver between

3. To remove the clip from the adjustment screw assembly, hold

5. Remove the drive ring and spring.

7. Tighten the spring setter as a tool (99828 Z0062) to the hous-

8. After removing the spring setter as a tool, remove the spring

Key point of reassembly

2. Assemble the boot and the cap assembly to the wedge.

7. After inserting the sleeve assembly into the housing, tighten

14. The expander assembly has different convergence stroke

BRAKE DRUM INSIDE DIAMETER, BRAKE DRUM

Anchor pin outside diameter

Brake shoe bushing inside diameter

Clearance between anchor pin and brake shoe bush-

Return spring free length

Adjust screw assembly’s clip holding torque

Revolution torque of sleeve assembly

Wedge spring tension

Wear of housing inside diameter

REPAIR AND REPLACEMENT

2. Align holes on lining to those on shoe, and insert and swage

1 Rivet guide 2 Brake shoe 3 Rivet

BRAKE SHOE BUSHING

SHOE CLEARANCE ADJUSTMENT (PRIMARY

* The maintenance standard indicates the clearance in use.

5. Install the dust cover firmly.

REPLACEMENT TIMING OF BRAKE LINING

BRAKE ASSEMBLY BPL41 TYPE

Camshaft type (Rear front)

Camshaft type (Rear rear)

DISASSEMBLY AND REASSEMBLY

Disassembly sequence (Assembly is done in the reverse sequence of disassembly)

Camshaft type (Rear front)

Disassembly sequence (Assembly is done in the reverse sequence of disassembly)

Camshaft type (Rear rear)

Disassembly sequence (Assembly is done in the reverse sequence of disassembly)

Disassembly sequence (assembly is done in the reverse sequence of disassembly)

Key point of disassembly

2. camshaft type (Rear front) only

2. To remove the clip from the adjustment screw assembly, hold

4. Remove the drive ring and spring.

6. Tighten the spring setter as a tool (99828 Z0062) to the hous-

7. After removing the spring setter as a tool, remove the spring

Key point of reassembly

2. Assemble the boot and the cap assembly to the wedge.

7. After inserting the sleeve assembly into the housing, tighten

14. The expander assembly has different convergence stroke

Tightening torque [N•m {kgf•m}]: 137 - 157 {14.0 - 16.0}

2. Before installing the brake chamber assembly, make sure

Tightening torque [N•m {kgf•m}]: 167 - 186 {17.0 - 19.0}

5. Install the roller pin paying attention to its installation direction,

<Wedge type and camshaft type>

2. Install the return spring assembly using return spring tool