brake rotor TOYOTA TERCEL 1985 Repair Manual

BRAKE SYSTEM - TroubleshootingBR.3
TROU BLESHOOTING (Cont'd)
ProblemPossible causeRemedyPage
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Snapping or clicking
noise when brakes
are applied
Drum brakes - brake shoes binding
at backing plate ledges
Drum brakes - backing plate ledgesworn
Drum brakes - loose or missing
hold down spring
Drum brakes - loose set bolt
at backing plate
Disc brakes - rust on front edge of
inboard shoes
Disc brakes - loose or missing pad
support plate
Disc brakes - loose installation
bolt
Disc brakes - wear on slide bushing
Lubricate
Replace and lubricate ledges
Replace
E,
Tisnteffit'
Inspect lubricate, replace if
necessary
Replace
Tighten
Replace
BR-22
BR-22
BR-22
BR-22
BR.1 6
BR-1 6
BR-1 6
BR-1 6
Scraping or grinding
noise when brakes
are applied
Worn brake linings
Caliper to wheel or rotor interference
Dust cover to rotor or drum
interference
other brake system components:
Warped or bent brake backing
plate or splash shield, cracked
drums or rotors
Tires rubbing against chassis and
body
Replace, refinish drums or
rotors if heavily scored
Replace as required
Correct or replace
lnspect or service
Inspect or service
BR-16,22
BR.1 8
BR-l8,22
BR-h1N,22
%

BR-4 BRAKE SYSTEM - Troubleshooting
TROU BLESHOOTI NG (Cont'd)
ProblemPossible causeRemedyPage
Squeaking, squealing
groaning or chatter-
ing noise when brakes
are applied
Note: Brake friction
materials inherently
generate noise and
heat in order to
dissipate energy.
As a result
occasional squeal
is normaland is
aggravated by severe
environmetal condi-
tions such as cold,
heat, wetness, snow,
salt mud, etc.
This occasional
squeal is not a func-
tional problem and
does not indicate
any loss of brake
effectiveness
Brake drums and linings rotors and
pads worn or scored
Disc brakes - missing or damaged
brake pad anti-squeal shim
Disc brakes - burred or rusted calipers
Dirty, greased, contaminated or
glazed linings
lmproper lining parts
Maladjustment of brake pedal or
booster push-rod
Drum brakes - weak damaged or
incorrect shoe hold down springs, loose
or damaged shoe hold down spring pins
springs and grooved backing plate
ledges
Inspect, service or repalce
Replace
Clean or deburr
Clean or replace
Inspect for conect usage
replace
lnspect and adjust
Inspect service or replace
BR-16,22
BR.l 6
BR-1 8
BR-16,22
BR-'t6,22
BR-6,15
8R.22
Squealing and
squeaking noise
when brakes are
not applied
Bent or warped backing plate causing
interference with drum
lmproper machining of drum causing
interference with backing plate or shoe
Maladjustment of brake pedal or
booster push-rod
Poor return of brake booster or master
cylinder or wheel cylinder
Disc brakes - rusted, stuck
Other brake system, components:
Loose or extra parts in brakes
Rear drum adjustment too tight
causing lining to glaze
Worn, damaged or insufficiently
lubricated wheel bearings
Service or replace
Replace drum
Inspect and adjust
Inspect, service or replace
Inspect lubricate as necessary
Inspect, service, replace as
required
BR-22
8R.22
BR-6,15
BR-g,15,22
BR.1 6
BR-16,22

BRAKE SYSTEM - TroubleshootingBR-5
TROUBLESHOOTING (Cont'dl
ProblemPossible causeRemedyPage
Squealing and
squeaking noise
when brakes are
not applied (cont'd)
Drum brakes - weak, damaged or
incorrect shoe hold down springs
Drum brakes - grooved backing plate
ledges
lmproper positioning of pad in caliper
Outside diameter of rotor rubbing
caliper housing
Housing installation of disc brake
pad support plate
Inspect, service or replace
Inspect, service or replace
Inspect and service
Inspect, service or replace
Correct
BR-22
BR-22
BR-l 6
BR-l 6
BR-1 6
Groaning, clicking
or rattling noise
when brakes are
not applied
Stones or foreign material trapped
inside wheel covers
Loose wheel hub nuts
Disc brakes - failure of shim
Disc brakes - wear on slide bushing
Disc brakes - loose installation
bolt
Maladjustment of brake pedal or
booster push-rod
Disc brakes - poor return of piston
Drum brakes - loose or extra parts
Worn, damaged or dry wheel bearings
Remove stones, etc.
Tighten to correct torque and re-
place if stud holes are elongated
lnspect, replace if necessary
Inspect, replace if necessary
Inspect, tighten if necessary
lnspect and adjust
Inspect, service or replace
Inspect remove or service
lnspect lubricate or replace
BR-18,22
BR.1 6
BR.1 6
BR-1 6
BR-6,15
BR.1 8
B,R.22

BR-l6BRAKE SYSTEM - Front Brake
FRONT BRAKE
COMPONENTS
I
IREPLACEMENT OF BRAKE PADS
. lf a squeaking noise occurs while braking, inspect the
. brake pads. Brake squeak will occur when the gap be-
tween the pad wear indicator plate and rotor disc reaches
about 2.5 mm (0.098 in.).
1. REMOVE FRONT WHEET
Rqmove the wheel and temporarily fasten the rotdfu discwith the wheel nuts. ;:E "'
2. INSPECT PAD LINING THICKNESS
Check the pad thickness through the cylinder inspection' hole and replace pads if not within specification.
Standard
Minimum
1O.0 mm (0.394-in.l
1.0 mm (0.039 in.)
\_ [-5s ntzst IFlexible Hose--\\>.;lco
Ja-- |I 'r fa-l
235 117,231
900 165,88)j Torque Plate
Leh
A\H)
Rotor Disc
Anti-squeal shim __Anti-squeal
I Spring
-cm (ft-lb, N.m)
8ao?36

l'-
BRAKE SYSTEM - Front Brake
,ritl t'i'.ihffi:ir ''$,8R.17
3. REMOVE CYLINDER FROM TOROUE PLATE
(a) Remove the two installation bolts from the torque
plate.
(b) Remove the brake cylinder and suspend it so the
hose is not stretched.
NOTE: Do not disconnect the brake hose.
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REMOVE FOLLOWING PARTS:
(a) Two anti-squeal springs
(b) Two brake pads
(d ."Two anti-squeal shims
(d) 'Two pad wear indicator plates
(e) .'FoUr support plates
CHECK ROTOR DISC THICKNESS(See*step 2 on page BR-l91
CHECK ROTOR DISC RUNOUT(See step 3 on page BR-2OI
INSTALL NEW PAD SUPPORT PLATES
4.
5.
6.
7.
$
INSTALL NEW PADS
(a) Install new pad wear indicator plates to each pad.
NOTE: Be sure the arrow on the pad we*fiQicator plate
is pointing in the rotating direction of thd diiHt_
(b) Install new anti-squeal shims to each pad.
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# BRo281
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BRAKE SVSTEM - Front Brake8R.19
2. REMOVE CYLINDER BOOT SET RING AND CYLINDER
BOOT
Using a screwdriver, remove the set ring and boot.
3. REMOVE PISTON FROM CYLINDER
(a) Put a piece of cloth or such between the piston and
cylinder.
(d Use compressed air to remove the piston from the
cylinder.
WARNING: Do not place your fingers in front of the
piston when using compressed air.
- REMOVE PISTON SEAL FROM BRAKE CYLINDER
Using a screwdriver, remove the piston seal.
INSPECTION AND REPAIR OF FRONT BRAKE
COMPONENTS
1. TNSPECT PAD LINING THICKNESS
Standard thickness: 10.O mm (0.394 in.)
Minimum thickness: 1.0 mm (0.039 in.l
Replace the pad if the thickness is less than minimum (the
1.0 mm slit is no longer visible) or if it shows signs of
uneven wear.
INSPECT ROTOR DISC THICKNESS
Standard thickness: 1 1.0 mm (0.433 in.l
Minimum thickness: 10.0 mm {0r39a in.}
lf the disc is scored or worn, or if thickness is less than
minimum, repair or replace the disc.
4.
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BR-2OBRAKE SYSTEM - Front Brake
3. INSPECT ROTOR DISC RUNOUT
Measure the rotor disc runout at 1O mm (0.39 in.) from the
outer edge of the rotor disc.
Maximum disc runout: 0.15 mm (0.0059 in.l
lf the runout is greater than maximum, replace the disc.
NorE: Before measuring the runout check that the front
bearing play is within specification.
4. IF NECESSARY, REPLACE ROTOR DISC
(d Remove the torque plate from the knuckle.
(b) Remove the wheel nuts of the temporarily installed
disc and pull off the rotor disc from the axle hub.
(c) Temporarily install a new rotor disc with the wheel
nuts.
(d) Install the torque plate onto the knuckle.
Torque: 900 kg-cm (65 ft-lb, 88 N'm)
ASSEMBLY OF CYLINDER
(See page BR-161
1. APPLY LITHUM SOAP BASE GLYCOL GREASE
TO PARTS INDICATED BY ARROWS
2. INSTALL PISTON SEAL AND PISTON IN CYLINDER
INSTALL CYLINDER BOOT AND SET RING IN
CYLINDER
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3.
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