Rear disc brake repair procedures

Removal

1. 1
   Loosen the wheel nuts slightly. Raise the vehicle and make sure it is securely supported.
2. 2
   Remove the rear wheel and tire (A) from the rear hub.

   Tightening torque: 107.9–128 N·m

   

3. 3
   Remove the parking brake cable retainer (A).

   

4. 4
   Pull the operating lever counterclockwise, then pull the cable (A) from the caliper.

   

5. 5
   Loosen the guide rod bolts and remove the caliper body (A).

   Tightening Torque: 21.6–31 N·m

   

6. 6
   Remove the pad return spring (A).

   

7. 7
   Remove the brake pad (A).

   

8. 8
   Remove the pad retainer (A).

   

9. 9
   Loosen the caliper mounting bolts and remove the caliper support (A).

   Tightening torque: 63.7–74 N·m

   

10. 10
    Loosen the screw and remove the brake disc (A).

    Tightening torque: 4.9–5.9 N·m

    

Replacement

1. 1
   Loosen the wheel nuts slightly. Raise the vehicle and make sure it is securely supported.
2. 2
   Remove the rear wheel and tire (A) from the rear hub.

   

3. 3
   Remove the parking brake cable retainer (A).

   

4. 4
   Pull the operating lever counterclockwise, then pull the cable (A) from the caliper.

   

5. 5
   Loosen the guide rod bolt, then lift the caliper body (A).

   

6. 6
   Replace the guide rod and boot (A) with new ones.

   

7. 7
   Install the caliper body (A).

   Tightening Torque: 21.6–31 N·m

   

8. 8
   Install the rear wheel and tire (A).

   Tightening torque: 107.9–128 N·m

   

Installation

1. 1
   To install, reverse the removal procedure.
2. 2
   When installing, push and turn the piston into the caliper body until it is fully retracted.

   

3. 3
   After installation, bleed the brake system. (Refer to Brake System - "Brake Bleeding") (Refer to Brake System - "ABS Bleeding") (Refer to Brake System - "ESP Bleeding")

Inspection

1. 1
   Inspect the brake disc for damage and cracks.
2. 2
   Remove all rust and contamination from the surface, and measure the disc thickness at at least 8 points at equal distances (5 mm) from the outer edge of the brake disc. Brake disc thickness - Standard: 10 mm (0.394 in.) - Maximum wear limit (2WD): 8.4 mm (0.33 in.) - Maximum wear limit (4WD): 8.0 mm (0.31 in.) - Thickness variation: less than 0.01 mm (0.0003 in.)

   

3. 3
   If wear exceeds the service limit, replace the discs and pads as a set, left and right of the vehicle.
4. 4
   Position the dial indicator approximately 5 mm (0.2 in) from the outer edge of the brake disc and measure the disc runout.

   Brake disc runout - Limit: 0.04 mm (0.0016 in.) or less (new)

   

5. 5
   If brake disc runout exceeds the limit, replace the disc, then measure the runout again.
6. 6
   If runout cannot be corrected by changing the position of the brake disc, replace the brake disc.

Adjustment

1. 1
   Remove the floor console to access the adjusting nut.
2. 2
   Loosen the parking brake cable until both control levers are fully in the OFF position.
3. 3
   Bring the brake pads into operating position by depressing the brake pedal. Pump the pedal several times until resistance is felt.
4. 4
   Tighten the parking brake cable by turning the adjusting nut until the control levers on both calipers lift from the stopper to the distance (A) and (D) between the operating lever (B) and the stopper (C).

   Distance (A + D): Max. 3 mm (0.12 in.)

   

5. 5
   Install the floor console.
6. 6
   The parking brake lever in the vehicle must be in the fully released position.
7. 7
   If the parking brake cables have been replaced, apply the parking brake with maximum force several times to stretch the parking brake cables, then adjust the control as described above.
8. 8
   Check that the wheels turn freely.
9. 9
   Road test.