TOYOTA TERCEL 1985 Repair Manual

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INSPECT BRAKE LINING AND DRUM FOR PROPER
CONTACT
Replace the brake shoe or lathe the brake drum as necess-
4ry.
INSPECT WHEET CYLINDER FOR CORROSION OR
DAMAGE
INSPECT BACKING PLATE FOR WEAR OR DAMAGE
INSTALLATION OF REAR BRAKE
(See page BR-291
1. APPLY LITHIUM SOAP BASE GLYCOL GREASE
TO FOLLOWING PABTS:
(d Two piston cups
(b) Two pistons
2. ASSEMBLE WHEEL CYLINDER
(a) lnstall two new piston cups to each piston, check
that the flanges of the cups are pointed inward.
(b) Install the two pistons and spring into the wheel
cylinder.
(c) Install two new boots.
3. INSTALL WHEEL CYLINDER
Installthe wheelcylinder on the backing plate with the two
bolts.
Torque: 1OO 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 (11 ft-lb, 15 N.ml
4.
5.
Pistoncu'
^cloqO
fl@6alA"
YrlI I Piston
I SPring
Boot

BRAKE SYSTEM - Rear Brake {Wagon FWD)8R.33
5. APPLY HIGH-TEMPERATURE GREASE TO
FOLLOWING PARTS:
H 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 TEVER TO REAR SHOE
(a) Temporarily install the levers and shim with a new C-
washer.
(d Using a feeler gauge, measure the clearance between
the shoe and lever.
Standard clearance: O - 0.35 mm (0 - 0.0138 in.l
lf not within specification, adjust with a shim.
Shim thicknesses mm (in.)
o.2 (0.008) | 0.5 (0.020)
0.3 (0.012) | 0.6 (0.024)
o.4 (0.016) | o.g (0.035)
(c) Using pliers, stake the C-washer.
7.INSTALL STRUT ONTO REAR SHOE
Set the strut and return spring in place
adjusting lever spring.
Shim
and install the

BR-34BRAKE SYSTEM - Rear Brake (Wagon FWD)
Left-hand Threads
Left Wheel
Right-hand Threads
Right Wheel
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Front
.|
80939 8R0253
INSTALT REAR SHOE
CAUTION: Do not allow oil or groase to get on the
rubbing face.
(a) Using pliers, connect the parking brake cable to the
lever.
(b) Pass the parking brake cable through the notch in the
anchor plate.
(c) 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.
(d) Install the hold-down spring, retainers and pin.
INSTALL FRONT SHOE
CAUTION: Do not allow oil or grease to get on the
rubbing face.
(d lnstall 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 hold-down spring, retainers and pin.
(d) Using SST, connect the return spring.
ssr 09703-30010
8.
9.

BRAKE SYSTEM - Rear Brake (Wason FWD)BR-35
1O. CHECK OPERATION OF AUTOMATIC ADJUSTER
MECHANISM
(d 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.
Adjust the strut length to the shortest possible
amount.
Install the drum.
Pull the parking brake lever all the way up.
CHECK CLEARANCE BETWEEN BRAKE SHOES AND
DRUM
(a) 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 conect shoe
clearance.
Shoe clearance: 0.6 mm (0.024 in.l
lf inconect check the parking brake system.
INSTALL BRAKE DRUM
INSTALL REAR WHEEL
FILI BRAKE RESERVOIR WITH BRAKE FLUID AND
BLEED BRAKE SYSTEM(See page BR-71
CHECK FOR FLUID LEAKAGE
(b)
(c)
(d)
11.
12.
13.
14.
15.

BR-36 BRAKE SYSTEM - Rear Brake (Wagon 4WD)
Wagon 4WD
COMPONENTS
Strut and Return Spring
O C-Washer
$ry"<'i
shoe
lotAnchor Spring
Automatic Adjusting Lever
arking Brake Lever
6f,Aai""tins Shim
Rear Shoe
Hold-down Spring
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{A
TK
Front
Backing Ptate
O: Non-reusable part
Wheel Cylinder
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6 \
q \\
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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.)
Minimum thickness: 1.0 mm (0.039 in.)
2. REMOVE REAR WHEEL
3. REMOVE BRAKE DRUM
lf the brake drum cannot be easily removed, do the follow-
ing procedure:
(a) Insert a screwdriver through the hole in the backing
plate, and hold the automatic adjusting lever away
from the adjusting bolt.
(d Using another screwdriver, reduce the brake shoe
adjustment by turning the adjusting bolt.

aBRAKE SYSTEM - Rear Brake (Wagon 4WD)8R.37
4. REMOVE FRONT SHOE
(d Using SST, remove the return spring.
ssT 09703-30010
(b) Remove the hold-down spring.
(c) Remove the front shoe and the anchor spring.
5. REMOVE REAR SHOE
(a) Remove the hold-down spring.
(b) Using pliers, disconnect the parking brake cable from
the lever and remove the rear shoe together with the
strut.
6. REMOVE STRUT FROM REAR SHOE
(a) Remove the adjusting lever spring.
(b) Remove the strut.
7. 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.
DISCONNECT BRAKE TUBE FROM WHEEL CYLINDER
Using SST, disconnect the line. Use a container to catch
the brake fluid.
ssr 09751-3601 1
REMOVE WHEEL CYLINDER
Remove the two bolts and wheel cylinder.
8.
9.

8R.38BRAKE SYSTEM - Rear Brake (Wagon 4WD)
Piston cup
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i *^m.GSDW)'"i.
lK3r)Y*
Am'Q)\gr---..- I
\J/ SPring
10. REMOVE FOLLOWING PARTS FROM WHEEL
CYLINDER:
(a) Two boots
b) Two pistons
(c) 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: 2O1.O 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.l
Minimum thickness: 1.0 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 all of the brake shoes.
3. INSPECT BRAKE LINING AND DRUM FOR PROPER
CONTACT
Replace the brake shoe or lathe the brake drum as neces-
sary.
4. INSPECT WHEEL CYLINDER FOR CORROSION OR
DAMAGE
5. INSPECT BACKING PLATE FOR WEAR OR DAMAGE
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BRAKE SYSTEM - Rear Brake (Wagon 4WD)8R.39
Apply Grease
INSTALLATION OF REAR BRAKE
(See page BR-361
1. APPLY LITHIUM SOAP BASE GLYCOL GREASE
TO FOLLOWING PARTS:
H Two piston cups
(d Two pistons
2. ASSEMBLE WHEEL CYLINDER
(d Install two new piston cups to the pistons.
(d Install the two pistons and spring into the wheel
cylinder. Check that the flanges of the piston are
pointed inward.
(c) Install two new boots.
3. INSTALL WHEEL CYLINDER
Installthe wheelcylinder 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 (11 ft-lb, 15 N.ml
5. APPTY HIGH TEMPERATURE GREASE TO
FOLLOWING PARTS:
(a) Backing plate and brake shoe contact points
(b) Anchor plate and brake shoe contact points
(d Strut and adjusting bolt contact points
(d) Strut and brake shoe contact points
Piston cup Piston
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d@*''*,J."n

BR.4OBRAKE SYSTEM - Rear Brake (Wagon 4WD)
6. INSTALL PARKING BRAKE LEVER AND AUTOMATIC
ADJUSTING LEVER TO REAR SHOE
(a) Temporarily installthe levers and 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.)
lf not within specification, adjust with a shim.
Shim thicknesses mm (in.)
0.2 (o.oo8) | 0.5 (0.020)
o.3 (0.012) I 0.6 (0.024)
o.4 (0.016) I o.s (0.035)
(c) Using pliers, stake the C-washer.
7.INSTALL STRUT ONTO REAR SHOE
Set the strut and return spring in place
adjusting lever spring.
and install the
Left-hand ThreadsRight-hand Threads
pVe
Front
f
Front
+
Left WheelRight Wheel
8RO256 8R0257

BRAKE SYSTEM - Rear Brake (Wagon 4WD)8R.41
8. INSTALL REAR SHOE
CAUTION: Do not allow oil or grease to get on the
rubbing face.
H 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) lnstall the pin and the shoe hold-down spring.
9. INSTALL FRONT SHOE
CAUTION: Do not allow oil or 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 and pin.
(d) Using SST, connect the return spring.
ssr 09703-30010
10. 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.