Toyota Camry

 XV30 (2002–2006) Service Manual

Brake
Rear disc brake

COMPONENTS

OVERHAUL

HINT:

• COMPONENTS:

• Overhaul the RH side by the same procedures with LH side.

• Two types of brake pad exist; one is with slit and the other without slit.

1. REMOVE REAR WHEEL

2. DRAIN BRAKE FLUID

NOTICE: Wash off the brake fluid immediately if it comes into contact with a painted surface.

3. DISCONNECT REAR LH FLEXIBLE HOSE

1.  Remove the union bolt and a gasket from the disc brake cylinder, then disconnect the flexible hose from the disc brake cylinder.

   HINT: Gasket has 2 types: 2−piece type and 1−piece type.

4. REMOVE REAR DISC BRAKE CYLINDER SLIDE PIN

1. TMC made: Remove the cylinder slide pin.

2. TMMK made: Remove the cylinder slide pin and cylinder slide bush.

5. REMOVE REAR DISC BRAKE CYLINDER ASSY LH

1. TMC made: Lift up the disc brake cylinder and remove the disc brake cylinder.

2. TMMK made: Remove the cylinder slide pin and disc brake cylinder.

6. REMOVE DISC BRAKE PAD KIT REAR (PAD ONLY)

1. Remove the 2 brake pads with the anti−squeal shim.

7. REMOVE REAR DISC BRAKE ANTI SQUEAL SHIM KIT

1. Remove the 2 anti−squeal shims and pad wear indicator from each of 2 brake pads.

2. TMC made: Remove the 2 pad wear indicator plates from each of 2 brake pads.

3. TMMK made: Remove the pad wear indicator plate from inner pad.

8. REMOVE REAR DISC BRAKE PAD SUPPORT PLATE

1.  Remove the rear disc brake pad support plate No.1.

9. REMOVE REAR DISC BRAKE PAD SUPPORT PLATE

1. Remove the rear disc brake pad support plate No.2.

10. REMOVE REAR DISC BRAKE BUSH DUST BOOT

1. TMC made: Remove the rear disc brake bush dust boot.

2. TMMK made: Remove the 2 rear disc brake bush dust boots.

11. REMOVE REAR DISC BRAKE CYLINDER MOUNTING LH

1. TMC made: Using a hexagon wrench (f8 mm), remove the cylinder slide pin.

2. Remove the 2 bolts and cylinder mounting LH.

12. REMOVE CYLINDER BOOT

1. Using a screwdriver, remove the set ring and disc cylinder boot.

13. REMOVE REAR DISC BRAKE PISTON

1. Place a piece of cloth or similar, between the piston and the disc brake cylinder.

2. Use compressed air to remove the piston from the disc brake cylinder.

CAUTION: Do not place your fingers in front of the piston when using compressed air.

NOTICE: Do not spatter the brake fluid.

Remove rear disc brake piston

14. REMOVE PISTON SEAL

1. Using a screwdriver, remove the piston seal from the brake cylinder.

NOTICE: Do not damage the inner cylinder and the cylinder groove.

15. REMOVE REAR DISC BRAKE BLEEDER PLUG CAP

16. REMOVE REAR DISC BRAKE BLEEDER PLUG

17. INSPECT BRAKE CYLINDER AND PISTON

1. Check the cylinder bore and piston for rust or scoring.

18. INSPECT PAD LINING THICKNESS

1. Using a ruler, measure the pad lining thickness.

   Standard thickness: 10.0 mm (0.394 in.) Minimum thickness: 1.0 mm (0.039 in.)

19. INSPECT REAR DISC BRAKE PAD SUPPORT PLATE

1. Make sure that they have sufficient rebound, no deformation cracks or wear, and have had all rust and dirt cleaned off.

20. INSPECT REAR DISC BRAKE PAD SUPPORT PLATE

1. Make sure that they have sufficient rebound, no deformation cracks or wear, and have had all rust and dirt and cleaned off.

21. INSPECT DISC THICKNESS

1. Using a micrometer, measure the disc thickness.

   Standard thickness: 12.0 mm (0.472 in.) Minimum thickness: 10.5 mm (0.413 in.)

 
Inspect disc thickness

22. REMOVE PARKING BRAKE SHOE ADJUSTING HOLE PLUG

23. REMOVE REAR DISC

1. Put matchmarks on the disc and the axle hub.

2. Remove the disc.

24. INSTALL REAR DISC

1. Aligning the matchmarks, install the rear disc.

   HINT: When replacing the disc with new one, select the installation position where the disc has the minimum runout.

25. INSTALL PARKING BRAKE SHOE ADJUSTING HOLE PLUG

26. INSPECT DISC RUNOUT

1. Temporarily fasten the disc with hub nuts.

   Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)

2. Using dial indicator, measure the disc runout 10 mm (0.39 in.) away from the outer edge of the disc.

   Maximum disc runout: 0.15 mm (0.0059 in.)

3. If the disc’s runout is maximum value or greater, check the bearing play in the axial direction and check the axle hub runout. If the bearing play and axle hub runout are not abnormal, adjust the disc runout or grind it on a ”On−car” brake lathe.

Inspect disc runout

27.  ADJUST PARKING BRAKE SHOE CLEARANCE

28. TEMPORARILY TIGHTEN REAR DISC BRAKE BLEEDER PLUG

1. Temporarily tighten the bleeder plug to the disc brake cylinder.

29. INSTALL REAR DISC BRAKE BLEEDER PLUG CAP

30. INSTALL PISTON SEAL

1. Apply the lithium soap base glycol grease on a new piston seal.

2. Install the piston seal to the disc brake cylinder.

31. INSTALL REAR DISC BRAKE PISTON

1. Apply the lithium soap base glycol grease on the piston.

2. Install the piston to the disc brake cylinder.

NOTICE: Do not screw the piston forcedly in the disc brake cylinder.

32. INSTALL CYLINDER BOOT

1. Apply the lithium soap base glycol grease on a new cylinder boot.

2.  Install the cylinder boot to the disc brake cylinder.

   HINT: Install the boot securely to the grooves of the cylinder and piston.

3. Using a screwdriver, install a new set ring.

NOTICE: Do not damage the cylinder boot.

33. INSTALL REAR DISC BRAKE CYLINDER MOUNTING LH

1. Install the cylinder mounting LH with the 2 bolts.

   Torque: TMC made: 61.8 N·m (630 kgf·cm, 46 ft·lbf) TMMK made: 47 N·m (475 kgf·cm, 34 ft·lbf)

34. INSTALL REAR DISC BRAKE CYLINDER SLIDE PIN

1. TMC made: Using a hexagon wrench (8 mm), install the cylinder slide pin.

   Torque: 39.2 N·m (400 kgf·cm, 29 ft·lbf)

2. TMMK made: Install the cylinder slide pin with the cylinder slide bush.

   Torque: 43 N·m (440 kgf·cm, 32 ft·lbf)

35. INSTALL REAR DISC BRAKE CYLINDER SLIDE BUSH (TMC MADE)

1.  Apply the lithium soap base glycol grease on a new cylinder slide bush.

2. Install the cylinder slide bush to the disc brake cylinder assy.

Install rear disc brake cylinder slide bush (TMC made)

36. INSTALL REAR DISC BRAKE BUSH DUST BOOT

1. TMC made: Install the rear disc brake bush dust boot.

1. Apply the lithium soap base glycol grease to seal surface of a new bush dust boot.

2.  Install the bush dust boot to the cylinder slide pin.

2. TMMK made: Install the rear disc brake bush dust boot.

1. Apply the lithium soap base glycol grease to seal surface of a 2 new bush dust boots.

2. Install the 2 bush dust boots to the each cylinder slide pin.

Install rear disc brake bush dust boot

37. INSTALL REAR DISC BRAKE PAD SUPPORT PLATE

1.  Install the rear disc brake pad support plate No.1.

38. INSTALL REAR DISC BRAKE PAD SUPPORT PLATE

1. Install the rear disc brake pad support plate No.2.

39. INSTALL REAR DISC BRAKE ANTI SQUEAL SHIM KIT

1. Coat the both sides of No.1 anti−squeal shim with pad grease all over, and install the shim together with No.2 anti−squeal shim to each pad.

2. TMC made: Install the 2 pad wear indicator plates to the each of 2 brake pads.

NOTICE: When replacing worn pads, the anti−squeal shims must be replaced together with the pads.

3. TMMK made: Install the pad wear indicator plate to the inner pad.

NOTICE: When replacing worn pads, the anti−squeal shims must be replaced together with the pads.

40. INSTALL DISC BRAKE PAD KIT REAR (PAD ONLY)

1. Install the 2 brake pads with the anti−squeal shim.

NOTICE: There should be no oil or grease on to the friction surface of the pads and the disc.

41. INSTALL REAR DISC BRAKE CYLINDER ASSY LH (TMC MADE)

1. Apply the lithium soap base glycol grease to the cylinder slide pin.

2. Install the disc brake cylinder assembly rear LH to the cylinder slide pin.

42. INSTALL REAR DISC BRAKE CYLINDER SLIDE PIN

1. Apply the lithium soap base glycol grease to the cylinder slide pin.

2. Install and torque the cylinder slide pin to the disc brake cylinder assembly.

   Torque: TMC made: 34.3 N·m (350 kgf·cm, 25 ft·lbf) TMMK made: 43 N·m (440 kgf·cm, 32 ft·lbf)

43. CONNECT REAR LH FLEXIBLE HOSE

1. Connect a new gasket and flexible hose with the union bolt.

   Torque: 29.4 N·m (300 kgf·cm, 22 ft·lbf)

43. FILL RESERVOIR WITH BRAKE FLUID

44. BLEED MASTER CYLINDER SST 09023−00101

45. BLEED BRAKE LINE

46. CHECK FLUID LEVEL IN RESERVOIR

47. CHECK BRAKE FLUID LEAKAGE

48. INSTALL REAR WHEEL Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)

Brake system

Brake pedal support assy

Accelerator & brake pedal assy

Brake system

Brake master cylinder sub-assy

Brake booster assy

Front brake

Brake fluid

Rear disc brake

Rear drum brake

Brake actuator assy (W/O VSC)

Brake actuator assy (W/ VSC)

Speed front LH

Skid control

Yawrate

Steering

Adjustable pedal switch

Adjustable pedal relay

Brake pedal support assy