GSIC - Global Service Information Center

# REAR BRAKE (for 4WD) > INSTALLATION

## for Preparation Click here

1. INSTALL REAR BRAKE DRUM AND NEW GASKET

2. FILL RESERVOIR WITH BRAKE FLUID

Fluid:
  SAE J1703 or FMVSS No. 116 DOT3

3. BLEED AIR FROM BRAKE MASTER CYLINDER

HINT:

  If the master cylinder has been disassembled or if the reservoir becomes empty, bleed air from the master cylinder.

1. Using SST, disconnect the 2 brake lines from the master cylinder.

   SST
     09023-00101

1. Slowly depress and hold the brake pedal.

1. Cover the outer holes with your finger, and release the pedal.

1. Repeat the 2 previous steps 3 or 4 times.

1. Using SST, connect the 2 brake lines to the master cylinder.

   SST
     09023-00101

   Torque:
     15.2 N*m{ 155 kgf*cm , 11 ft.*lbf } without SST
     14 N*m{ 143 kgf*cm , 10 ft.*lbf } with SST

   HINT:
     Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

4. BLEED AIR FROM BRAKE LINE

1. Remove the bleeder plug cap.

1. Connect the vinyl tube to the bleeder plugs.

1. Depress the pedal several times, and then loosen the bleeder plug with the pedal depressed.

1. When fluid stops coming out, immediately tighten the bleeder plug. Then release the pedal.

1. Repeat the 2 previous steps until all the air in the brake fluid is gone.

1. Tighten the bleeder plug.

   Torque:
     10.8 N*m{ 110 kgf*cm , 8 ft.*lbf } for front brake
     11 N*m{ 112 kgf*cm , 8 ft.*lbf } for rear brake (2WD)
     10 N*m{ 102 kgf*cm , 7 ft.*lbf } for rear brake (4WD)

1. Install the cap.

1. Bleed air from the brake line for each wheel by repeating the above procedures.

5. BLEED AIR FROM CLUTCH LINE (M/T)

1. Remove the bleeder plug cap.

1. Connect the vinyl tube to the bleeder plug.

1. Depress the clutch pedal several times, and then loosen the bleeder plug with the pedal depressed.

1. At the point when fluid stops coming out, tighten the bleeder plug, and then release the clutch pedal.

1. Repeat the previous 2 steps until all the air in the fluid is completely bled out.

1. Tighten the bleeder plug.

   Torque:
     11 N*m{ 112 kgf*cm , 8 ft.*lbf }

1. Install the bleeder plug cap.

1. Check that all the air has been bled out of the clutch line.

6. CHECK BRAKE FLUID LEVEL IN RESERVOIR

1. Check the fluid level and add fluid if necessary.

   Fluid:
     SAE J1703 or FMVSS No. 116 DOT3

   HINT:
     Add fluid to a level between the reservoir's MIN and MAX lines.

7. CHECK FOR BRAKE FLUID LEAKAGE

8. INSTALL REAR WHEEL

Torque:
  105 N*m{ 1,070 kgf*cm , 77 ft.*lbf }

9. CHECK PARKING BRAKE LEVER TRAVEL

1. Pull the lever upward with a force of approximately 200 N (20 kgf, 44 lbf) and count the number of clicks.

   OK:
     7 to 9 clicks

10. ADJUST PARKING BRAKE LEVER TRAVEL

1. Remove the lock nut.

1. Turn the No. 1 wire adjusting nut until the lever travel is correct.

1. Tighten the lock nut.

   Torque:
     5.0 N*m{ 51 kgf*cm , 44 in.*lbf }

   HINT:
     If further adjustment is necessary, proceed to the next step.