TOYOTA TERCEL 1985 Repair Manual

BR-22BRAKE SYSTEM - Rear Brake (Sedan)
REAR BRAKE
Sedan
COMPONENTS
Backing Plate
Shoe
Adjusting Shim
O C-Washer
Adjusting Lever
Spring
Return Spring
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O: Non-reusable part
REMOVAL OF REAR BRAKE
1. INSPECT SHOE LINING THICKNESS
Remove the inspection hole plug, and check the shoe lin-
ing thickness through the hole.
lf less than minimum, replace the shoes.
Standard thickness: 4.0 mm (0.157 in.l
Minimum thickness: 1.0 mm (O.039 in.l
2. REMOVE REAR WHEEL
3. REMOVE BRAKE DRUM
(See step 2 on page RA-51
lf the brake drum cannot be easily removed, do the follow-
ing procedure:
(d Insert a screwdriver through the hole in the backing
plate, and hold the automatic adjusting lever away
from the adjusting bolt
(b) Using another screwdriver, reduce the brake shoe
adjustment by turning the adiusting bolt.

BRAKE SYSTEM - Rear Brake (Sedan)BR-23
REMOVE SHOE RETURN SPRING
Using a screwdriver, remove the return spring.
REMOVE SHOE RETURN SPRING CLAMP
Using a screwdriver, remove the clamp.
REMOVE FRONT SHOE
(a) Remove the hold-down spring, retainers and pin.
(b) Disconnect the anchor spring from the front shoe
and remove it.
REMOVE ANCHOR SPRING
8. REMOVE REAR SHOE
(d Remove the hold-down spring, retainers and pin.
(b) Using pliers, disconnect the parking brake cable from
the lever and remove the rear shoe together with the
strut.
9. REMOVE STRUT FROM REAR SHOE
(a) Remove the adjusting lever spring.
(b) Remove the strut.
10. REMOVE PARKING BRAKE LEVER AND AUTOMATIC
ADJUSTING LEVER FROM REAR SHOE
Using a screwdriver, pry out the C-washer and remove the
shim and levers.
4.
5.
6.
7.

.,ea-24BRAKE SYSTEM - Rear Brake (Sedan)
1 1. DISCONNECT BRAKE TUBE FROM WHEEL CYLINDER
Using SST, disconnect the line. Use a container to catch
the brake fluid.
ssr 09751-3601 1
12. REMOVE WHEET CYLINDER
Remove the two bolts and wheel cylinder.
REMOVE FOLLOWING
CYLINDER:
(d Two boots
(b) Two pistons
(c) Two piston cups
(d Spring
PARTS FROM WHEEL
INSPECTION OF REAR BRAKE COMPONENTS
1. INSPECT BRAKE DRUM INSIDE DIAMETER
Standard inside diameter: 180.0 mm (7.087 in.)
Maximum inside diameter: 181.0 mm (7.126 in.)
lf the drum is scored or worn, the brake drum may be
lathed to the maximum inside diameter.
NOTE: Perform operations with the following parts
removed:
(d Oil seal
(b) lnner and outer bearing
2. INSPECT BRAKE SHOE LINING THICKNESS
Standard thickness: 4.0 mm (0.157 in.l
Minimum thickness: 1.0 mm (0.039 in.)
lf the shoe lining is less than minimum or shows signs of
uneven wear, replace the brake shoes.
NOTE: lf the thickness of any brake shoe is not within
specification, replace all of the brake shoes.
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BRAKE SYSTEM - Rear Brake (Sedan)8R.25
Apply Grease
3. INSPECT BRAKE LINING AND DRUM FOR PROPER
CONTACT
Replace the brake shoe or lathe the brake drum as necess-
4ry.
4. INSPECT WHEEL CYLINDER FOR CORROSION OR
DAMAGE
5. INSPECT BACKING PLATE FOR WEAR OR DAMAGE
INSTALLATION OF REAR BRAKE
(See page BR-221
1. APPLY LITHIUM SOAP BASE GILYCOL GREASE
TO FOTLOWING PARTS:
(d Two piston cups
(b) Two pistons ,, ,
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2. ASSEMBLE WHEEL CYLINDER
(a) Install two new piston cups to the pistons.
(b) Install the two pistons and spring into the wheet
cylinder. Check that the flange of the pistons are
pointed inward.
(c) Install two new boots.
3. INSTALL WHEEL CYLINDER
Install the wheel cylinder on the backing plate with the two
bolts.
Torque: lOO kg-cm (7 ft-lb, 1O N.ml
4. CONNECT BRAKE TUBE TO WHEEL CYLINDER
Using SST, connect the brake tube.
ssT 09751 -3601 1
Torque: 155 kg-cm (11ft-lb, 15 N.ml
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BR-26BRAKE SYSTEM - Rear Brake {Sedan)
5. APPLY HIGH TEMPERATURE GREASE TO
FOLLOWING PARTS:
(a) Backing plate and brake shoe contact points
(b) Anchor plate and brake shoe contact points
(c) Strut and adjusting bolt contact points
(d) Strut and brake shoe contact points
6. INSTALL PARKING BRAKE LEVER AND AUTOMATIC
ADJUSTING LEVER TO REAR SHOE
(d Temporarily install the levers with the shim and a
new C-washer.
(d Using a feeler gauge, measure the clearance between
the shoe and lever.
Standard clearance: O - 0.35 mm (O - 0.0138 in.l
lf not within specification, adjust with a shim.
Shim thicknesses mm (in.)
0.2 (0.008) | 0.5 (0.020)
0.3 (0.012) | 0.6 (0.024)
0.4 (0.016) | 0.s (0.035)
(cl Using pliers, stake the C-washer.
INSTALL STRUT ONTO REAR SHOE
Set the strut in place and intall the adjusting lever spring.
7.
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BRAKE SYSTEM - Rear Brake (Sedan)B,R.27
Left-hand Threads
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Right-hand Threads
Right Wheel
Front
+
Front
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Left Wheel
8. INSTALL REAR SHOE
CAUTION: Do not allow grease to get on the rubbing
face
(a) Using pliers, connect the parking brake cable to the
lever.
(b) Set the rear shoe in place with the end of the shoe
inserted in the wheel cylinder and the other end in the
anchor plate.
(c) Install the pin and the shoe hold-down spring.
9. INSTALL FRONT SHOE
GAUTION: Do not allow grease to get on the rubbing
face
(a) Install the anchor spring between the front and rear
shoes.
(b) Set the front shoe in place with the end of the shoe
inserted in the wheel cylinder and the strut in place.
(c) Install the shoe hold-down spring, retainers and pin.
INSTALL SHOE RETURN SPRING CLAMP
INSTALL SHOE RETURN SPRING
Using a screwdriver, install the return spring.
10.
11.

8R.28BRAKE SYSTEM - Rear Brake (Sedan)
12. CHECK OPERATION OF AUTOMATIC ADJUSTER
MECHANISM
(a) Move the parking brake lever of the rear shoe back
and forth, as shown. Check that the adjusting bolt
turns.
lf the bolt does not turn, check for incorrect installation of
the rear brakes.
(b) Adjust the strut length to the shortest possible
amount.
(d lnstall the drum.
(d) Pull the parking brake lever all the way up.
13. CHECK CLEARANCE BETWEEN BRAKE SHOES AND
DRUM
h) Remove the drum.
(b) Measure the brake drum inside diameter and
diameter of the brake shoes. Check that the
difference between the diameters is the correct shoe
clearance.
Shoe clearance: 0.6 mm (0.O24 in.l
lf incorrect check the parking brake system.
14. INSTALL BRAKE DRUM AND ADJUST PRELOAD
(See page RA-61
15. INSTALL REAR WHEEL
16. FILL BRAKE RESERVOIR WITH BRAKE FLUID
AND BLEED BRAKE SYSTEM (See page BR-71
17. CHECK FOR FLUID LEAKAGE
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Wagon FWD
COMPONENTS
/a 7-Automatic Adjustiuu A Lever
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Parkirfs e,"x" / ///cc-Lever 4//Return Spring
Wheel Cylinder
Rear Shoe
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Anchor sprins I LZ/
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Front Shoe
Adjusting Lever Spring-.-Retainer- @ ^ Shoe Hold-Down Spring
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kg-cm (ft-lb, N'm):Tightening torque
| : Non-reusable part
Drum
100 (7, r0l
Backing Plate
REMOVAL OF REAR BRAKE
1. INSPECT SHOE LINING THICKNESS
Remove the inspection hole plug, and check the shoe lin-
ing thickness through the hole.
lf less than minimum, replace the shoes.
Standard thickness: 4.0 mm (0.157 in.l
Minimum thickness: 1.0 mm (0.039 in.l
2. REMOVE REAR WHEEL
3. REMOVE BRAKE DRUM
lf the brake drum cannot be easily removed, do the follow-
ing procedure:
(d Insert a screwdriver through the hole in the backing
plate, and hold the automatic adiusting lever away
from the adjusting bolt.
(b) Using another screwdriver, reduce the brake shoe
adjustment by turning the adjusting bolt.

4. REMOVE FRONT SHOE
(d Using SST, disconnect the return spring.
ssr 09703-30010
(d Remove the hold-down spring, retainers and pin.
(c) Disconnect the anchor spring from the front shoe
and remove it
REMOVE ANCHOR SPRING
6. REMOVE REAR SHOE
(a) Remove the hold-down spring, retainers and pin.
b) Using a screwdriver, disconnect the parking brake
cable from the anchor Plate.
(d Using pliers, disconnect the parking brake cable from
the lever and remove the rear shoe together with the
strut.
7. REMOVE STRUT FROM REAR SHOE
(a) Remove the adiusting lever spring.
(d Remove the strut together with the return spring.
8. REMOVE PARKING BRAKE LEVER AND
AUTOMATIC ADJUSTING LEVER FROM REAR SHOE
Using a screwdriver, pry out the C-washer and remove the
shim and levers.
5.
BRO337 BR0286

BRAKE SYSTEM - Rear Brake (Wagon FWD)8R.31
9. DISCONNECT BRAKE TUBE FROM WHEEL
CYLINDER
Using SST, disconnect the line. Use a container to catch
the brake fluid.
10. REMOVE WHEEL CYLINDER
Remove the two bolts and wheel cylinder.
11. REMOVE FOLLOWING PARTS FROM WHEEL
CYLINDER:
(a) Two boots
(b) Two pistons
(c) Two piston cups
(d) Spring
INSPECTION OF REAR BRAKE COMPONENTS
1. INSPECT BRAKE DRUM INSIDE DIAMETER
Standard inside diameter: 200.0 mm (7.874 in.l
Maximum inside diameter: 201.0 mm (7.913 in.)
lf the drum is scored or worn, the brake drum may be
lathed to the maximum inside diameter.
2. INSPECT BRAKE SHOE LINING THICKNESS
Standard thickness: 4.0 mm (0.157 in.)
Minimum thickness: 1.O mm {0.039 in.l
lf the shoe lining is less than minimum or shows signs of
uneven wear, replace the brake shoes.
NOTE: lf the thickness of any brake shoe is not within
specification, replace the all of the brake shoes.
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IPiston
Boot
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