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BRAKE SYSTEM Return To Main Table of Contents GENERAL BRAKE PEDAL 11 MASTER CYLINDER 15 BRAKE BOOSTER BRAKE LINE 25 FRONT DISC BRAKE (SUMITOMO) 27 FRONT DISC BRAKE (TOKICO) 35 REAR DRUM BRAKE 39 PARKING BRAKE 43 GENERAL GENERAL SPECIFICATIONS Master cylinder Type Bore Tandem type Fluid level sensor Provided 20.64 mm (0.81 in.), fitted with brake booster Brake booster Type Effective dia of power cylinder Vacuum type Boosting ratio, with brake pedal applied with a force of 160 N (36 Ibs.) 3.0 : 180 mm (7.1 in.) Proportioning valve Cut-in pressure (Split point) 3.1 MPa (455 psi) 3.6 MPa (525 psi) Reducing ratio 3.33 : 3.7 : Manufacturer Sumitomo Kelsey-hayes Type Disc Floating type with ventilated disc Disc O.D 229 mm (9.02 in.) 242 mm (9.53 in.) Pad thickness 10.0 mm (0.39 in.) 10 mm (0.39 in.) Disc thickness 13 mm (0.512 in.) 19 mm (0.75 in.) Cylinder bore 51.1 mm (2.01 in.) 51.1 mm (2.01 in.) Clearance adjustment Automatic adjustment Automatic adjustment Manufacturer Sumitomo (PS 15) Tokico (CR20V) Front brakes Rear brakes Type Drum I.D Leading-trailing, drum Brake lining thickness 4.3 mm (0.17 in.) Cylinder bore 19.05 mm (0.75 in.) Clearance adjustment Automatic adjustment (with use of parking brake) 180 mm (7.1 in.) Parking brake Mechanical brake acting on rear wheels Type Activation Cable Brake type Lever type 58-2 GENERAL SERVICE STANDARD Standard value Brake pedal height Stop light switch outer case to pedal arm clearance Brake pedal free play Brake pedal to floorboard clearance Booster push rod to master cylinder piston clearance Parking brake lever stroke adjustment Limit Master cylinder to piston clearance Pad thickness Disc thickness Sumitomo Tokico Disc runout Sumitomo Tokico Drum brake lining thickness Brake drum inner diameter Wheel cylinder to piston clearance TIGHTENING TORQUE Master cylinder Master cylinder to brake booster Brake fluid reservoir to master cylinder bolt Piston stopper Brake booster to booster mounting holder Booster mounting holder to pedal support member Brake booster hose fitting to manifold Bleeder screw Brake line flare nuts Brake hose Proportioning valve mounting bolt Disc brake (SUMITOMO) Caliper inner and outer bridge bolts Caliper assembly to knuckle Disc to hub Disc brake (TOKICO) Cylinder mounting bolt Cylinder pin bolt Caliper assembly to knuckle Disc to hub Leading-trailing drum brake Wheel cylinder Braking plate to housing 182-187 mm (7.2-7.4 in.) 0.5-1.0 mm (0.02-0.04 in.) 10-15 mm (0.4-0.6 in.) 40 mm (1.6 in.) or more 0.40-0.80 mm (0.016-0.031 in.) 5-7 clicks 0.15 mm (0.006 in.) 1.0 mm (0.04 in.) 11.4 mm (0.45 in.) 17.0 mm (0.67 in.) 0.15 mm (0.006 in.) 0.15 mm (0.006 in.) 1.0 mm (0.04 in.) 182 mm (7.2 in.) 0.15 mm (0.006 in.) Nm kg.cm Ib.ft 7.8-12 1.5-2.9 1.5-2.9 7.8-12 7.8-12 7.8-12 6.9-8.8 13-17 12-16 7.8-12 80-120 15-30 15-30 80-120 80-120 80-120 70-90 130-170 120-160 80-120 5.8-8.7 1.1-2.2 1.1-2.2 5.8-8.7 5.8-8.7 5.8-8.7 5.1-6.5 9.4-12 8.7-11 5.8-8.7 78-93 59-78 49-59 800-950 600-800 500-600 58-69 43-58 36-43 22-31 34-44 64-74 49-59 220-320 350-450 650-750 500-600 16-23 25-32 47-54 36-43 7.8-12 49-59 80-120 500-600 5.8-8.7 36-43 LUBRICANTS Brake fluid Recommended lubricant Quantity DOT or equivalent As required 58-3 GENERAL SPECIAL TOOLS 58-4 GENERAL TROUBLESHOOTING Symptom Noise or vibration when brakes are applied Vehicle pulls to one side when brakes are applied Insufficient braking power Increased pedal stroke (Reduced pedal to floorboard clearance) Remedy Probable cause Backing plate or caliper improperly mounted Correct Loose backing plate or caliper mounting bolts Retighten Unevenly worn or cracked brake drum or brake disc Replace Foreign material in brake drum Clean Seized pad or lining contact surface Replace Excessive caliper to pad assembly clearance Correct Uneven pad contact Correct Lack of lubrication in sliding parts Lubricate Loose suspension parts Retighten Difference in left and right tire inflation pressure Adjust Inadequate contact of pad or lining Correct Grease or oil on pad or lining surface Replace Drum eccentricity or uneven wear Replace Incorrect wheel cylinder installation Correct Auto adjuster malfunction Correct Low or contaminated brake fluid Replenish or change Air in brake system Bleed the system Brake booster malfunction Correct Inadequate contact of pad or lining Correct Grease or oil on pad surface Replace Auto adjuster malfunction Correct Overheated brake rotor due to dragging of pad or lining Correct Clogged brake line Correct Proportioning valve malfunction Replace Air in brake system Bleed the system Brake fluid leaks Correct Auto adjuster malfunction Correct Excessive push rod to master cylinder clearance Adjust 58-5 GENERAL Symptom Brake drag Insufficient parking brake function 58-6 Probable cause Remedy Incomplete release of parking brake Correct Incorrect parking brake adjustment Adjust Weak brake pedal return spring Replace Clogged master cylinder return port Correct Broken rear drum brake shoe return spring Replace Lack of lubrication in sliding parts Lubricate Defective master cylinder check valve or piston return spring Replace Insufficient push rod to master cylinder clearance Adjust Worn brake lining Replace Grease or oil on lining surface Replace Parking brake cable sticking Replace Auto adjuster malfunction Correct Excessive parking brake lever stroke Adjust the parking brake lever stroke or check the parking brake cable routing GENERAL SERVICE BRAKE PEDAL INSPECTION AND ADJUSTMENT Measure the brake pedal height as illustrated If the brake pedal height is not within the standard value, adjust as follows Pedal height (from upper surface of the panel floor to top of the brake pedal pad) A [Standard value] 182-187 mm (7.2-7.4 in.) (a) Move the stop light switch to a position where it does not contact the brake pedal arm (b) Adjust the brake pedal height by turning the operating rod with pliers (with the operating rod lock nut loosened), until the correct clearance is obtained (c) Adjust the stop light switch until the dimension between the outer case of the stop light switch and the brake pedal arm reaches the standard value, and then lock the switch in place with lock nut Dimension B [Standard value] 0.5-1.0 mm (0.02-0.04 in.) While the engine is stopped, apply the brake pedal two or three times After thus eliminating the vacuum in the power brake booster, press the pedal down by hand, and confirm that the amount of movement before resistance is correct Brake pedal free play C [Standard value] 10-15 mm (0.4-0.6 in.) If the free play is less than the standard value, confirm that the clearance between the outer case of the stop light switch and brake pedal is within the standard value Start the engine, apply the brake pedal with approximately 500 N (110 Ibs.) of force, and measure the clearance between the brake pedal and the floor board Pedal to floorboard clearance D when pedal is depressed [Pedal depressing force: about 500 N (110 Ibs.)] [Standard value] 40 mm (1.6 in.) or more If the pedal to floor board clearance is less than the standard value, correct it according to the troubleshooting chart 58-7 GENERAL PARKING BRAKE STROKE ADJUSTMENT Pull the brake lever with a force of approx 196 N (44 Ibs.), and count the numbers of clicks Parking brake lever stroke [Standard value] 5-7 clicks If the number of notches is not the standard value, adjust the cable length with the adjusting nut of the equalizer CAUTION: (a) Adjust the right and left cables so that when the lever is pulled, their lengths will be almost equal (b) If the rear cable is too taut when the lever is returned, the adjuster lever will not engage the adjuster and the automatic shoe clearance adjustment mechanism will not function Loosen the parking brake switch mounting bolt to adjust the switch so that the indicator light will go out when the brake lever is fully released, and will light with the lever pulled one notch After the adjustment, check to ensure that the rear brakes not drag with the parking brake lever released 58-8 GENERAL BRAKE BOOSTER OPERATING TEST Test Without a Tester For simple checking of the brake booster operation, carry out the following tests: Run the engine for one or two minutes, and then stop it Depress the brake pedal several times with normal pressure If the pedal depresses fully the first time but gradually becomes higher when depressed succeeding times, the booster is operating properly If the pedal height remains unchanged, the booster is defective With the engine stopped, depress the brake pedal several times with the same foot pressure to make sure that the pedal height will not change Then depress the brake pedal and start the engine If the pedal moves downward slightly, the booster is in good condition If there is no change, the booster is defective With the engine running, depress the brake pedal and then stop the engine Hold the pedal depressed for 30 seconds If the pedal height does not change, the booster is in good condition, if the pedal rises, the booster is defective If the above three tests are okay, the booster performance can be determined as good If one of the above three tests is not okay, the check valve, vacuum hose, or booster will be defective PROPORTIONING VALVE FUNCTION TEST Connect two pressure gauges, one each to the input side and output side of the proportioning valve, as illustrated With the brakes applied, measure the input pressure and the output pressure If the measured pressures are within the permissible ranges shown, the proportioning valve is good If the measured pressures are not within the permissible ranges, replace the proportioning valve as an assembly Reconnect the brake tubes in their original positions and bleed the system NOTE: This figure indicates only when the pressure of the master cylinder is rising 58-9 GENERAL BRAKE BLEEDING The brake hydraulic system should be bled whenever the brake tube, brake hose, master cylinder or wheel cylinder has been removed or whenever the brake pedal feels spongy when depressed Bleed the brake system in the sequence shown in the illustration Recommended brake fluid DOT or equivalent CAUTION (a) Use the specified brake fluid Avoid using a mixture of the specified brake fluids (b) If brake fluid is exposed to the air, it will absorb moisture; As water is absorbed from the atmosphere, the boiling point of the brake fluid will be lowered and the braking performance will be seriously impaired For this reason, use a hermetically sealed liter (1.06 U.S.qts., 0.88 Imp.qts.) or 0.5 liter (0.52 U.S.qts., 0.44 Imp.qts.) brake fluid container (c) Firmly close the cap of the brake fluid container after use 58-10 ... 9. 4-1 2 8. 7-1 1 5. 8-8 .7 7 8-9 3 5 9-7 8 4 9-5 9 80 0-9 50 60 0-8 00 50 0-6 00 5 8-6 9 4 3-5 8 3 6-4 3 2 2-3 1 3 4-4 4 6 4-7 4 4 9-5 9 22 0-3 20 35 0-4 50 65 0-7 50 50 0-6 00 1 6-2 3 2 5-3 2 4 7-5 4 3 6-4 3 7. 8-1 2 4 9-5 9 8 0-1 20 50 0-6 00 5. 8-8 .7... 7. 8-1 2 1. 5-2 .9 1. 5-2 .9 7. 8-1 2 7. 8-1 2 7. 8-1 2 6. 9-8 .8 1 3-1 7 1 2-1 6 7. 8-1 2 8 0-1 20 1 5-3 0 1 5-3 0 8 0-1 20 8 0-1 20 8 0-1 20 7 0-9 0 13 0-1 70 12 0-1 60 8 0-1 20 5. 8-8 .7 1. 1-2 .2 1. 1-2 .2 5. 8-8 .7 5. 8-8 .7 5. 8-8 .7 5. 1-6 .5... Leading-trailing drum brake Wheel cylinder Braking plate to housing 18 2-1 87 mm (7. 2-7 .4 in.) 0. 5-1 .0 mm (0.0 2-0 .04 in.) 1 0-1 5 mm (0. 4-0 .6 in.) 40 mm (1.6 in.) or more 0.4 0-0 .80 mm (0.01 6-0 .031