Master cylinder | ||
Type | Tandem type | |
I.D. | 23.8 mm (0.94 in.) : CBS (Conventional Brake System) 25.4 mm (1.0 in.) : ABS (Antilock Brake System) | |
Fluid level sensor | Provided | |
Brake booster | ||
Type | Vacuum type with tandem booster | |
Effective dia. | 8 + 9 in. | |
Boosting ratio | 7.0 : 1 (CBS), 7.5 : 1 (ABS) | |
Front brake | ||
Type | Floating type with ventilated disc | |
Disc O.D. | 276 mm (10.87in.) : 2WD 294 mm (11.57in.) : 4WD | |
Disc thickness | 26 mm (1.02 in.) | |
Pad thickness | 10.5 mm (0.41 in.) | |
Cylinder I.D. | 42.9 mm (1.689 in.) (X2) | |
Rear disk brake | ||
Type | Floating type with solid disc | |
Disc O.D. | 284 mm (11.18 in.) | |
Disc thickness | 10 mm (0.39 in.) | |
Pad thickness | 10 mm (0.39 in.) | |
Cylinder I.D. | 38.2 mm (1.50 in.) | |
Parking brake | ||
ation | Mechanical brake acting on rear wheels | |
Type | Lever | |
Rear drum brake | ||
Type | Dual mode drum | |
Drum I.D. | 254 mm (10 in.) | |
Cylinder I.D. | 20.64 mm (0.81 in.) | |
Clearance adjustment | Automatic | |
Lining thickness | 4.5 mm (0.18 in.) | |
Standard value | ||
Brake pedal height | 208 (+5, -0) mm, (8.19 (+2, -0) in.) | |
Clearance between stop lamp switch outer case and pedal stopper | 0.5-1.0 mm (0.020-0.040 in.) | |
Brake pedal free play | 3-8 mm (0.118-0.315 in.) | |
Clearance between booster push rod and master cylinder piston | 0 (at 500 mmHg vacuum) | |
Clearance between brake pedal and floor board | 44 mm (1.73 in.) | |
Parking brake lever stroke (when lever assembly is pulled with 196N (20kg, 44lb) force 7 clicks | 44 mm (1.73 in.) | |
Service limit | ||
Front disc brake pad thickness | 2.0 mm (0.079 in.) | |
Front disc thickness (minimum) | 24.4 mm (0.96 in.) | |
Front disc runout | 0.04 mm ( 0.0016 in.) | |
Front disc thickness variation | 0.005 mm (0.0002 in.) | |
Rear disc brake pad thickness | 2.0 mm (0.079 in.) | |
Rear disc thickness | 8.4 mm (0.33 in.) | |
Rear drum I.D. | 256 mm (10.08 in.) | |
Rear brake lining thickness | 1.5 mm (0.06 in.) | |
Nm | Kg·cm | lb·ft | |
Master cylinder to booster mounting | 8-12 | 80-120 | 5.9-8.8 |
Brake booster mounting nut | 13-16 | 130-160 | 9.6-11.8 |
Brake booster vacuum hose fitting to surge tank | 15-18 | 150-180 | 11.1-13.3 |
Bleeder screw | 7-9 | 70-90 | 5.2-6.6 |
Brake flare nut, brake hose | 13-17 | 130-170 | 9.5-12.5 |
Proportioning valve mounting bolt | 35-55 | 350-550 | 25.8-40.6 |
Caliper guide rod bolt | 22-32 | 220-320 | 16.2-23.6 |
Caliper assembly to knuckle | |||
Front | 80-100 | 800-1000 | 59-73.8 |
Rear | 50-60 | 500-600 | 36.9-44.3 |
Brake hose to front caliper | 25-30 | 250-300 | 18.4-22.1 |
Wheel cylinder mounting bolt | 12-18 | 120-180 | 8.9-13.3 |
Parking brake mounting bolt | 17-26 | 170-260 | 12.5-19.2 |
caution Replace the self-locking nuts with new ones after removal. |
Trouble symptom | Probable cause | Remedy |
Noise or vibration when brakes are applied | Caliper improperly mounted Loose caliper mounting bolts Unevenly worn or cracked brake drum or brake disc Foreign material in brake drum Seized pad or lining contact surface Excessive clearance between pad assembly and caliper Uneven pad contact Lack of lubrication in sliding parts Loose suspension parts Excessive of disc runout Excessive variation of disc thickness | Correct Retighten Replace Clean Replace Correct Correct Lubricate Retighten Replace disc Replace disc |
Vehicle pulls to one side when brakes are applied | Difference in left and right tire inflation pressure Inadequate contact of pad or lining Grease or oil on pad or lining surface Drum warped or uneven wear Incorrect wheel cylinder installation Auto adjuster malfunction | Adjust Correct Replace Replace Correct Correct |
Insufficient braking power | Low or deteriorated brake fluid Air in the brake system Brake booster malfunction Inadequate contact of pad or lining Grease or oil on pad or lining surface Auto adjuster malfunction Overheated brake rotor due to dragging of pad or lining Restricted brake line Proportioning valve malfunction | Refill or change Bleed the system Correct Correct Replace Correct Correct Replace Replace |
Increased pedal stroke required (Reduced clearance between pedal and floorboard) | Air in the system Brake fluid leaks Excessive push rod to master cylinder clearance | Bleed the system Correct Adjust |
Brake drag | Incomplete release of parking brake Incorrect parking brake adjustment Worn brake pedal return spring Restricted master cylinder return port Broken rear drum brake shoe return spring Lack of lubrication in sliding parts Defective master cylinder check valve or piston return spring | Adjust Adjust Replace Correct Replace Lubricate Replace |
Insufficient parking brake function | Worn brake lining or pad Grease or oil on lining or pad surface Parking brake cable sticking Auto adjuster malfunction Excessive parking brake lever stroke | Replace Replace Replace Correct Adjust the parking brake lever stroke or check the parking brake cable routing |
Master cylinder | ||
Type | Tandem type | |
I.D. | 23.8 mm (0.94 in.) : CBS (Conventional Brake System) 25.4 mm (1.0 in.) : ABS (Antilock Brake System) | |
Fluid level sensor | Provided | |
Brake booster | ||
Type | Vacuum type with tandem booster | |
Effective dia. | 8 + 9 in. | |
Boosting ratio | 7.0 : 1 (CBS), 7.5 : 1 (ABS) | |
Front brake | ||
Type | Floating type with ventilated disc | |
Disc O.D. | 276 mm (10.87in.) : 2WD 294 mm (11.57in.) : 4WD | |
Disc thickness | 26 mm (1.02 in.) | |
Pad thickness | 10.5 mm (0.41 in.) | |
Cylinder I.D. | 42.9 mm (1.689 in.) (X2) | |
Rear disk brake | ||
Type | Floating type with solid disc | |
Disc O.D. | 284 mm (11.18 in.) | |
Disc thickness | 10 mm (0.39 in.) | |
Pad thickness | 10 mm (0.39 in.) | |
Cylinder I.D. | 38.2 mm (1.50 in.) | |
Parking brake | ||
ation | Mechanical brake acting on rear wheels | |
Type | Lever | |
Rear drum brake | ||
Type | Dual mode drum | |
Drum I.D. | 254 mm (10 in.) | |
Cylinder I.D. | 20.64 mm (0.81 in.) | |
Clearance adjustment | Automatic | |
Lining thickness | 4.5 mm (0.18 in.) | |
Standard value | ||
Brake pedal height | 208 (+5, -0) mm, (8.19 (+2, -0) in.) | |
Clearance between stop lamp switch outer case and pedal stopper | 0.5-1.0 mm (0.020-0.040 in.) | |
Brake pedal free play | 3-8 mm (0.118-0.315 in.) | |
Clearance between booster push rod and master cylinder piston | 0 (at 500 mmHg vacuum) | |
Clearance between brake pedal and floor board | 44 mm (1.73 in.) | |
Parking brake lever stroke (when lever assembly is pulled with 196N (20kg, 44lb) force 7 clicks | 44 mm (1.73 in.) | |
Service limit | ||
Front disc brake pad thickness | 2.0 mm (0.079 in.) | |
Front disc thickness (minimum) | 24.4 mm (0.96 in.) | |
Front disc runout | 0.04 mm ( 0.0016 in.) | |
Front disc thickness variation | 0.005 mm (0.0002 in.) | |
Rear disc brake pad thickness | 2.0 mm (0.079 in.) | |
Rear disc thickness | 8.4 mm (0.33 in.) | |
Rear drum I.D. | 256 mm (10.08 in.) | |
Rear brake lining thickness | 1.5 mm (0.06 in.) | |
Nm | Kg·cm | lb·ft | |
Master cylinder to booster mounting | 8-12 | 80-120 | 5.9-8.8 |
Brake booster mounting nut | 13-16 | 130-160 | 9.6-11.8 |
Brake booster vacuum hose fitting to surge tank | 15-18 | 150-180 | 11.1-13.3 |
Bleeder screw | 7-9 | 70-90 | 5.2-6.6 |
Brake flare nut, brake hose | 13-17 | 130-170 | 9.5-12.5 |
Proportioning valve mounting bolt | 35-55 | 350-550 | 25.8-40.6 |
Caliper guide rod bolt | 22-32 | 220-320 | 16.2-23.6 |
Caliper assembly to knuckle | |||
Front | 80-100 | 800-1000 | 59-73.8 |
Rear | 50-60 | 500-600 | 36.9-44.3 |
Brake hose to front caliper | 25-30 | 250-300 | 18.4-22.1 |
Wheel cylinder mounting bolt | 12-18 | 120-180 | 8.9-13.3 |
Parking brake mounting bolt | 17-26 | 170-260 | 12.5-19.2 |
caution Replace the self-locking nuts with new ones after removal. |
Trouble symptom | Probable cause | Remedy |
Noise or vibration when brakes are applied | Caliper improperly mounted Loose caliper mounting bolts Unevenly worn or cracked brake drum or brake disc Foreign material in brake drum Seized pad or lining contact surface Excessive clearance between pad assembly and caliper Uneven pad contact Lack of lubrication in sliding parts Loose suspension parts Excessive of disc runout Excessive variation of disc thickness | Correct Retighten Replace Clean Replace Correct Correct Lubricate Retighten Replace disc Replace disc |
Vehicle pulls to one side when brakes are applied | Difference in left and right tire inflation pressure Inadequate contact of pad or lining Grease or oil on pad or lining surface Drum warped or uneven wear Incorrect wheel cylinder installation Auto adjuster malfunction | Adjust Correct Replace Replace Correct Correct |
Insufficient braking power | Low or deteriorated brake fluid Air in the brake system Brake booster malfunction Inadequate contact of pad or lining Grease or oil on pad or lining surface Auto adjuster malfunction Overheated brake rotor due to dragging of pad or lining Restricted brake line Proportioning valve malfunction | Refill or change Bleed the system Correct Correct Replace Correct Correct Replace Replace |
Increased pedal stroke required (Reduced clearance between pedal and floorboard) | Air in the system Brake fluid leaks Excessive push rod to master cylinder clearance | Bleed the system Correct Adjust |
Brake drag | Incomplete release of parking brake Incorrect parking brake adjustment Worn brake pedal return spring Restricted master cylinder return port Broken rear drum brake shoe return spring Lack of lubrication in sliding parts Defective master cylinder check valve or piston return spring | Adjust Adjust Replace Correct Replace Lubricate Replace |
Insufficient parking brake function | Worn brake lining or pad Grease or oil on lining or pad surface Parking brake cable sticking Auto adjuster malfunction Excessive parking brake lever stroke | Replace Replace Replace Correct Adjust the parking brake lever stroke or check the parking brake cable routing |
