Toyota Avalon (XX50): Rear Brake

Toyota Avalon (XX50) 2019-2022 Service & Repair Manual / Brake / Brake (rear) / Rear Brake

Components

COMPONENTS

ILLUSTRATION

*1	NO. 2 PARKING BRAKE WIRE ASSEMBLY	*2	PARKING BRAKE ACTUATOR ASSEMBLY
*3	O-RING	-	-
	Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping": Nm (kgfcm, ft.*lbf)	●	Non-reusable part
	Lithium soap base glycol grease	-	-

ILLUSTRATION

*1	REAR DISC BRAKE ANTI-SQUEAL SHIM KIT	*2	REAR DISC BRAKE CYLINDER ASSEMBLY
*3	REAR DISC BRAKE PAD	*4	REAR FLEXIBLE HOSE
*5	REAR NO. 1 DISC BRAKE ANTI-SQUEAL SHIM	*6	REAR NO. 2 DISC BRAKE ANTI-SQUEAL SHIM
*7	REAR DISC BRAKE ANTI-SQUEAL SHIM	*8	REAR DISC BRAKE PAD WEAR INDICATOR PLATE
*9	GASKET	*10	UNION BOLT
	Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping": Nm (kgfcm, ft.*lbf)	●	Non-reusable part
	Disc brake grease	-	-

ILLUSTRATION

*1	REAR DISC	*2	REAR DISC BRAKE BUSHING DUST BOOT
*3	REAR DISC BRAKE CYLINDER MOUNTING	*4	REAR DISC BRAKE PAD SUPPORT PLATE
*5	REAR NO. 1 DISC BRAKE CYLINDER SLIDE PIN	*6	REAR NO. 2 DISC BRAKE CYLINDER SLIDE PIN
*7	REAR DISC BRAKE CYLINDER SLIDE BUSHING	-	-
	Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping": Nm (kgfcm, ft.*lbf)	●	Non-reusable part
	Lithium soap base glycol grease	-	-

ILLUSTRATION

*1	CYLINDER BOOT	*2	PISTON SEAL
*3	REAR DISC BRAKE BLEEDER PLUG	*4	REAR DISC BRAKE BLEEDER PLUG CAP
*5	REAR DISC BRAKE PISTON	*6	REAR DISC BRAKE CYLINDER
	Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping": Nm (kgfcm, ft.*lbf)	●	Non-reusable part
	Lithium soap base glycol grease	-	-

Disassembly

DISASSEMBLY

CAUTION / NOTICE / HINT

CAUTION:

If the rear disc brake cylinder assembly has been disassembled, perform air bleeding for the rear disc brake cylinder assembly.

for Gasoline Model: Click here

for HV Model: Click here

NOTICE:

Make sure not to scratch, damage or apply excessive force to any of the internal components of the rear disc brake cylinder.
To prevent rusting on the inside of the rear disc brake cylinder, perform the rear disc brake piston removal and installation quickly.
Do not clean the interior of the rear disc brake cylinder with brake cleaner.
Do not remove any parts unless specifically instructed to do so, and only remove the parts indicated.
Make sure to enter pad replacement mode before removing the rear disc brake cylinder assembly.
for Gasoline Model: Click here

for HV Model: Click here

PROCEDURE

1. REMOVE CYLINDER BOOT

(a) Using a screwdriver with its tip wrapped with protective tape, remove the cylinder boot from the rear disc brake cylinder.

NOTICE:

Do not damage the inner surface or cylinder boot groove of the rear disc brake cylinder.

*a	Protective Tape

2. REMOVE REAR DISC BRAKE PISTON

(a) Place a piece of cloth between the rear disc brake piston and rear disc brake cylinder.

Cloth

(b) Apply compressed air to remove the rear disc brake piston from the rear disc brake cylinder.

Do not hold the rear disc brake cylinder with any part of your hand between the rear disc brake cylinder and rear disc brake piston.
Do not place any part of your hand in front of the rear disc brake piston when using compressed air as a severe injury may result.

NOTICE:

Do not allow any brake fluid to spatter.

3. REMOVE PISTON SEAL

(a) Using a screwdriver with its tip wrapped with protective tape, remove the piston seal from the rear disc brake cylinder.

NOTICE:

Do not damage the inner surface or piston seal groove of the rear disc brake cylinder.
Do not allow the nut to rotate. If the nut is accidentally allowed to rotate, return it to its original position.

*a	Protective Tape
*b	Nut

4. REMOVE REAR DISC BRAKE BLEEDER PLUG CAP

(a) Remove the rear disc brake bleeder plug cap from the rear disc brake bleeder plug.

5. REMOVE REAR DISC BRAKE BLEEDER PLUG

(a) Remove the rear disc brake bleeder plug from the rear disc brake cylinder.

Inspection

INSPECTION

PROCEDURE

1. INSPECT BRAKE CYLINDER AND PISTON

(a) Check the rear disc brake cylinder bore and rear disc brake piston for rust and scoring. If necessary, replace the rear disc brake cylinder and rear disc brake piston.

2. INSPECT PAD LINING THICKNESS

(a) Using a ruler, measure the rear disc brake pad lining thickness.

Standard Thickness:

9.5 mm (0.374 in.)

Minimum Thickness:

1.0 mm (0.0394 in.)

If a rear disc brake pad lining thickness is less than the minimum thickness, replace the rear disc brake pads.

HINT:

Be sure to check the rear disc thickness when replacing the rear disc brake pads with new ones.

Ruler

3. INSPECT REAR DISC BRAKE PAD SUPPORT PLATE

(a) Make sure that the rear disc brake pad support plates have sufficient rebound, no deformation, cracks or wear, and that all rust and dirt is cleaned off. If necessary, replace the rear disc brake pad support plates.

4. INSPECT DISC THICKNESS

(a) Using a micrometer, measure the rear disc thickness.

Standard Thickness:

12.0 mm (0.472 in.)

Minimum Thickness:

10.5 mm (0.414 in.)

If the rear disc thickness is less than the minimum thickness, replace the rear disc.

*a	Micrometer

5. INSPECT DISC RUNOUT

(a) Inspect the rear axle hub bearing looseness and rear axle hub runout.

Click here

(b) Temporarily install the rear disc with the 5 hub nuts.

Torque:

103 N·m {1050 kgf·cm, 76 ft·lbf}

(c) Using a dial indicator with magnetic base, measure the disc runout 10 mm (0.394 in.) from the outer edge of the rear disc.

Maximum Disc Runout:

0.15 mm (0.00591 in.)

NOTICE:

Keep the magnet of the dial indicator away from the rear axle hub and bearing assembly.

If the runout exceeds the maximum value, change the installation position of the rear disc to minimize the runout. If the runout exceeds the maximum even when the installation position is changed, grind the rear disc. If the rear disc thickness is less than the minimum, replace the rear disc.

*a	Dial Indicator with Magnetic Base

(d) Remove the 5 hub nuts and rear disc.

Installation

INSTALLATION

CAUTION / NOTICE / HINT

NOTICE:

Immediately after installing the brake pads, the braking performance may be reduced. Always perform a road test in a safe place while paying attention to the surroundings.
After replacing the rear disc brake pads, always perform a road test to check the braking performance and check for vibrations.
When the brake pedal is first depressed after replacing the brake pads or pushing back the disc brake piston, DTC C1214 may be stored. As there is no malfunction, clear the DTC. (for HV Model)
While the auxiliary battery is connected, even if the power switch is off, the brake control system activates when the brake pedal is depressed or any door courtesy switch turns on. Therefore, when servicing the brake system components, do not operate the brake pedal or open/close the doors while the auxiliary battery is connected. (for HV Model)

HINT:

Use the same procedure for the RH side and LH side.
The following procedure is for the LH side.

PROCEDURE

1. INSTALL REAR DISC

(a) Align the matchmarks of the rear disc and rear axle hub and bearing assembly, and install the rear disc.

NOTICE:

When replacing the rear disc with a new one, select the installation position where the rear disc has minimal runout.

Matchmark

2. INSTALL REAR DISC BRAKE CYLINDER MOUNTING

(a) Install the rear disc brake cylinder mounting to the rear axle carrier sub-assembly with the 2 bolts.

Torque:

107 N·m {1091 kgf·cm, 79 ft·lbf}

3. INSTALL REAR DISC BRAKE BUSHING DUST BOOT

(a) Apply a light layer of lithium soap base glycol grease to the entire circumference of 2 new rear disc brake bushing dust boots.

HINT:

Apply more than 0.3 g (0.01 oz) of lithium soap base glycol grease to each rear disc brake bushing dust boot.

Lithium Soap Base Glycol Grease

(b) Install the 2 rear disc brake bushing dust boots to the rear disc brake cylinder mounting.

4. INSTALL REAR DISC BRAKE CYLINDER SLIDE PIN

Lithium Soap Base Glycol Grease

(a) Apply a light layer of lithium soap base glycol grease to the contact surface of the rear No. 2 disc brake cylinder slide pin.

(b) Install a new rear disc brake cylinder slide bushing to the rear No. 2 disc brake cylinder slide pin.

Lithium Soap Base Glycol Grease

(c) Apply a light layer of lithium soap base glycol grease to the sliding part and the sealing surfaces of the rear No. 1 disc brake cylinder slide pin and rear No. 2 disc brake cylinder slide pin.

(d) Install the rear No. 1 disc brake cylinder slide pin and rear No. 2 disc brake cylinder slide pin to the rear disc brake cylinder mounting.

*1	Rear No. 1 Disc Brake Cylinder Slide Pin
*2	Rear No. 2 Disc Brake Cylinder Slide Pin

(e) Push the rear No. 1 disc brake cylinder slide pin and rear No. 2 disc brake cylinder slide pin into each rear disc brake bushing dust boot to engage the pins to the boots.

5. INSTALL REAR DISC BRAKE PAD SUPPORT PLATE

(a) Install the 4 rear disc brake pad support plates to the rear disc brake cylinder mounting.

NOTICE:

Be sure to install each rear disc brake pad support plate in the correct position and direction.

6. INSTALL REAR DISC BRAKE ANTI-SQUEAL SHIM KIT

Click here

7. INSTALL REAR DISC BRAKE PAD

(a) Install the 2 rear disc brake pads to the rear disc brake cylinder mounting.

NOTICE:

Install the rear disc brake pad so that the rear disc brake pad wear indicator plate is mounted on the lower side of the vehicle.

HINT:

If the rear disc brake pad has an identification mark, be sure to confirm the installation location.

*a	Inner Side (White)
*b	Outer Side (White)

8. INSTALL REAR DISC BRAKE CYLINDER ASSEMBLY

(a) Hold the 2 rear disc brake cylinder slide pins, and install the rear disc brake cylinder assembly to the rear disc brake cylinder mounting with 2 bolts.

Torque:

34.3 N·m {350 kgf·cm, 25 ft·lbf}

NOTICE:

If bleeding of air from the rear brake cylinder assembly will be performed, reuse the bolts. If bleeding of air from the rear brake cylinder assembly will not be performed, install new bolts.

9. INSTALL PARKING BRAKE ACTUATOR ASSEMBLY

Click here

10. CONNECT NO. 2 PARKING BRAKE WIRE ASSEMBLY

Click here

11. CONNECT REAR FLEXIBLE HOSE

(a) Connect the rear flexible hose to the rear disc brake cylinder assembly with a new union bolt and a new gasket.

Torque:

29 N·m {296 kgf·cm, 21 ft·lbf}

NOTICE:

Install the rear flexible hose lock securely into the lock hole in the rear disc brake cylinder assembly.

12. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL (for HV Model)

(a) Connect the reservoir level switch connector.

(b) Connect the cable to the negative (-) auxiliary battery terminal.

Click here

(1) Turn the power switch on (READY).

(2) Depress the brake pedal and release it.

(3) Clear the DTCs.

Click here

13. BLEED BRAKE LINE

for Gasoline Model: Click here

for HV Model: Click here

14. BLEED REAR DISC BRAKE CYLINDER ASSEMBLY (for Gasoline Model)

CAUTION:

If the rear disc brake cylinder assembly has been disassembled, perform air bleeding for the rear disc brake cylinder assembly.

HINT:

Use the same procedure for the RH side and LH side.
The following procedure is for the LH side.
While performing air bleeding of the rear disc brake cylinder assembly, the bolts can be reused during the bleeding procedure. After air bleeding is complete, replace the bolts with new ones.

(a) Perform the procedure to enter rear disc brake pad replacement mode 5 times.

Click here

(b) Release the parking brake.

(d) Hold the 2 rear disc brake cylinder slide pins and remove the 2 bolts and separate the rear disc brake cylinder assembly from the rear disc brake cylinder mounting.(*1)

*a	Turn
*b	Hold

(e) Hold the rear disc brake cylinder assembly horizontally, then tilt it 45° toward the bleeder plug side as shown in the illustration.(*2)

(f) Temporarily install the rear disc brake cylinder assembly to the rear disc brake cylinder mounting with the 2 bolts.(*3)

(g) Remove the brake master cylinder reservoir filler cap assembly.

(h) Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.

NOTICE:

Make sure that there is sufficient brake fluid in the reservoir.
Do not remove the filter from the brake master cylinder reservoir assembly and be sure to fill the brake master cylinder reservoir assembly with new brake fluid to avoid any potential contamination of the brake system. Contamination, for example by dirt particles or mineral oil, could lead to functional brake problems.
If brake fluid leaks onto any painted surface, immediately wash it off.

(i) Remove the rear disc brake bleeder plug cap.

(j) Connect a vinyl tube to the rear disc brake bleeder plug.

(k) Depress the brake pedal several times, and then loosen the rear disc brake bleeder plug with the pedal depressed.(*4)

(l) When fluid stops coming out, tighten the rear disc brake bleeder plug and release the brake pedal.(*5)

NOTICE:

Repeat steps (*4) through (*5) until there are no signs of air in the brake fluid.

(m) Repeat steps (*1) through (*5) 3 times.

NOTICE:

If there is still air in the system after performing steps (*1) through (*5) 3 times, repeat the steps (*1) through (*5) until the air has been bled.

(n) Tighten the rear disc brake bleeder plug completely.

Torque:

8.3 N·m {85 kgf·cm, 73 in·lbf}

(o) Install the rear disc brake bleeder plug cap.

(p) Hold the 2 rear disc brake cylinder slide pins, and install the rear disc brake cylinder assembly to the rear disc brake cylinder mounting with 2 new bolts.

Torque:

34.3 N·m {350 kgf·cm, 25 ft·lbf}

(q) Connect the No. 2 parking brake wire assembly connector to the parking brake actuator assembly.

(r) Inspect for brake fluid leaks.

(s) Inspect the brake fluid level in the reservoir.

Click here

(t) Install the brake master cylinder reservoir filler cap assembly.

15. BLEED REAR DISC BRAKE CYLINDER ASSEMBLY (for HV Model)

CAUTION:

If the rear disc brake cylinder assembly has been disassembled, perform air bleeding for the rear disc brake cylinder assembly.

NOTICE:

Perform air bleeding while maintaining the brake fluid level between the MAX and MIN lines on the brake fluid reservoir.
Do not allow brake fluid to contact any painted surface. If brake fluid leaks onto any painted surface, immediately wash it off.

HINT:

Use the same procedure for the RH side and LH side.
The following procedure is for the LH side.
While performing air bleeding of the rear disc brake cylinder assembly, the bolts can be reused during the bleeding procedure. After air bleeding is complete, replace the bolts with new ones.

(a) Perform the procedure to enter rear disc brake pad replacement mode 5 times.

Click here

(b) Release the parking brake.

(1) Disable brake control.

Click here

(2) Disconnect the No. 2 parking brake wire assembly connector.

Click here

(3) Hold the 2 rear disc brake cylinder slide pins and remove the 2 bolts and separate the rear disc brake cylinder assembly from the rear disc brake cylinder mounting.

*a	Turn
*b	Hold

(4) Hold the rear disc brake cylinder assembly horizontally, then tilt it 45° toward the bleeder plug side as shown in the illustration.

(5) Temporarily install the rear disc brake cylinder assembly to the rear disc brake cylinder mounting with the 2 bolts.

(6) Connect the No. 2 parking brake wire assembly connector.

Click here

(7) Connect the reservoir level switch connector.

(8) Connect the cable to the negative (-) auxiliary battery terminal.

Click here

(9) Turn the power switch on (READY).

(10) Depress the brake pedal and release it.

(11) Apply the parking brake.

(d) Enter ECB (Electronically Controlled Brake system) Invalid Mode.(*2)

NOTICE:

Performing the following procedure enters ECB (Electronically Controlled Brake system) Invalid Mode without using the Techstream.
ECB (Electronically Controlled Brake system) Invalid Mode allows the brake lines to be bled without using the Techstream.
The brake warning light blinks (yellow) to indicate that ECB (Electronically Controlled Brake system) Invalid Mode is selected.
Be sure to confirm that the brake warning light is blinking (yellow) throughout the brake line bleeding procedure.

If any of the following conditions are met, ECB (Electronically Controlled Brake system) Invalid Mode is canceled and the brake warning light (yellow) turns off. Do not allow ECB (Electronically Controlled Brake system) Invalid Mode to be canceled while bleeding the brake lines or DTCs may be stored.

The shift lever is moved from P to any other position.

The power switch is turned on (READY).

The power switch is turned off.

The parking brake is released.

The vehicle speed is more than 0 km/h (0 mph).

Do not rotate any brake disc while ECB (Electronically Controlled Brake system) Invalid Mode is selected.
Although the brake warning light (yellow) will blink and a buzzer will sound while performing brake line bleeding, this is not a malfunction.

(1) Perform the procedure listed below within 1 minute.

Turn the power switch on (IG) with the shift lever in P and parking brake applied.
Move the shift lever to N and then depress the brake pedal more than 8 times within 5 seconds.
Move the shift lever to P and then depress the brake pedal more than 8 times within 5 seconds.
Move the shift lever to N and then depress the brake pedal more than 8 times within 5 seconds.
Move the shift lever to P.

(2) Check that the brake warning light is blinking (yellow).

*a	Brake Warning Light (Yellow)

(e) Bleed the brake line.(*3)

(1) Remove the brake master cylinder reservoir filler cap assembly.

(2) Remove the rear disc brake bleeder plug cap.

(3) Connect a vinyl tube to the rear disc brake bleeder plug.

(4) Add brake fluid to the reservoir until the fluid level is between the MAX and MIN lines on the brake fluid reservoir.(*a)

(5) Depress the brake pedal several times, and then loosen the bleeder plug with the pedal depressed.(*b)

(6) When fluid stops coming out, tighten the rear disc brake bleeder plug and release the brake pedal.(*c)

(7) Repeat steps (*a) through (*c) until there are no signs of air in the brake fluid.

(f) Repeat steps (*1) through (*3) 3 times.

NOTICE:

If there is still air in the system after performing steps (*1) through (*3) 3 times, repeat the steps (*1) through (*3) until the air has been bled.

(g) Tighten the rear disc brake bleeder plug completely.

Torque:

8.3 N·m {85 kgf·cm, 73 in·lbf}

(h) Install the rear disc brake bleeder plug cap to the rear disc brake bleeder plug.

(i) Hold the 2 rear disc brake cylinder slide pins, and install the rear disc brake cylinder assembly to the rear disc brake cylinder mounting with 2 new bolts.

Torque:

34.3 N·m {350 kgf·cm, 25 ft·lbf}

(j) Inspect for brake fluid leaks.

(k) Adjust the brake fluid level in the reservoir.

Click here

(l) Install the brake master cylinder reservoir filler cap assembly.

(m) Turn the power switch off.

(n) Clear the DTCs.

Click here

16. INSTALL REAR WHEEL

Click here

17. NORMAL CONDITION RECOVERY

for HV Model: Click here

for Gasoline Model: Click here

Reassembly

REASSEMBLY

CAUTION / NOTICE / HINT

CAUTION:

If the rear disc brake cylinder assembly has been disassembled, perform air bleeding for the rear disc brake cylinder assembly.

for Gasoline Model: Click here

for HV Model: Click here

NOTICE:

Make sure not to scratch, damage or apply excessive force to any of the internal components of the rear disc brake cylinder.
To prevent rusting on the inside of the rear disc brake cylinder, perform the rear disc brake piston removal and installation quickly.
Do not clean the interior of the rear disc brake cylinder with brake cleaner.
Do not remove any parts unless specifically instructed to do so, and only remove the parts indicated.

PROCEDURE

1. TEMPORARILY TIGHTEN REAR DISC BRAKE BLEEDER PLUG

(a) Temporarily install the rear disc brake bleeder plug to the rear disc brake cylinder.

HINT:

Fully tighten the rear disc brake bleeder plug after bleeding the system.

2. INSTALL REAR DISC BRAKE BLEEDER PLUG CAP

(a) Install the rear disc brake bleeder plug cap to the rear disc brake bleeder plug.

3. INSTALL PISTON SEAL

(a) Apply lithium soap base glycol grease to the entire circumference of a new piston seal.

Lithium Soap Base Glycol Grease

(b) Install the piston seal to the rear disc brake cylinder.

NOTICE:

Do not damage the inner surface or piston seal groove of the rear disc brake cylinder.
Do not allow the nut to rotate. If the nut is accidentally allowed to rotate, return it to its original position.

4. INSTALL REAR DISC BRAKE PISTON

(a) Apply a light layer of lithium soap base glycol grease to the entire circumference of a new cylinder boot.

*1	Cylinder Boot
*2	Rear Disc Brake Piston
	Lithium Soap Base Glycol Grease

(b) Apply a light layer of lithium soap base glycol grease to the contact surfaces of the rear disc brake piston.

NOTICE:

The front and back sides of the cylinder boot are different. Make sure not to install the cylinder boot backwards.

*a	Front Side
*b	Back Side

(d) Install the rear disc brake piston to the rear disc brake cylinder.

NOTICE:

Install the rear disc brake cylinder so that its portions marked (A) fit into the indentations of the rear disc brake piston.
Do not forcibly install the rear disc brake piston into the rear disc brake cylinder.

*a	Indentations

(e) Install the cylinder boot to the rear disc brake cylinder as shown in the illustration.

NOTICE:

Do not damage the cylinder boot.
Securely install the cylinder boot into the groove of the rear disc brake cylinder and groove of the rear disc brake piston.

*1	Cylinder Boot
*2	Rear Disc Brake Cylinder
*3	Rear Disc Brake Piston

Removal

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed and installed, or replaced during rear brake removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure	Necessary Procedure	Effect/Inoperative Function when Necessary Procedure not Performed
1: for HV Model 2: When performing learning using the Techstream. Click here
Auxiliary battery terminal is disconnected/reconnected*1	Perform steering sensor zero point calibration	Lane Departure Alert System (w/ Steering Control)
		Pre-collision System
		Intelligent Clearance Sonar System*2
		Lighting System (for HV Model with Cornering Light)
	Memorize steering angle neutral point	Parking Assist Monitor System
	Memorize steering angle neutral point	Panoramic View Monitor System

NOTICE:

Immediately after installing the brake pads, the braking performance may be reduced. Always perform a road test in a safe place while paying attention to the surroundings.
After replacing the rear disc brake pads, always perform a road test to check the braking performance and check for vibrations.
When the brake pedal is first depressed after replacing the brake pads or pushing back the disc brake piston, DTC C1214 may be stored. As there is no malfunction, clear the DTC. (for HV Model)
While the auxiliary battery is connected, even if the power switch is off, the brake control system activates when the brake pedal is depressed or any door courtesy switch turns on. Therefore, when servicing the brake system components, do not operate the brake pedal or open/close the doors while the auxiliary battery is connected. (for HV Model)

HINT:

Use the same procedure for the RH side and LH side.
The following procedure is for the LH side.

PROCEDURE

1. PRECAUTION (for HV Model)

NOTICE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.
Click here
Make sure to read the precautions of the electric parking brake system before removing the rear brake assembly.
Click here

2. REMOVE REAR WHEEL

Click here

3. PERFORM REAR BRAKE PAD REPLACEMENT MODE

for Gasoline Model: Click here

for HV Model: Click here

4. DISABLE BRAKE CONTROL (for HV Model)

(a) Wait at least 2 minutes after turning the power switch off.

NOTICE:

When the brake pedal is depressed or the door courtesy switch is turned on even if the power switch is off, the brake control system activates. Therefore do not depress the brake pedal or open/close the doors until the reservoir level switch connector is disconnected.
Do not operate the electric parking brake switch assembly when the electric parking brake system is in rear brake pad replacement mode.

(b) Disconnect the reservoir level switch connector.

Click here

(d) Depress the brake pedal 40 times or more to return all the fluid in the accumulator back to the reservoir.

(e) Check that the brake pedal cannot be further depressed.

5. DRAIN BRAKE FLUID

NOTICE:

If brake fluid leaks onto any painted surface, immediately wash it off.

6. SEPARATE REAR FLEXIBLE HOSE

(a) Remove the union bolt and gasket, and disconnect the rear flexible hose from the rear disc brake cylinder assembly.

7. DISCONNECT NO. 2 PARKING BRAKE WIRE ASSEMBLY

Click here

8. REMOVE PARKING BRAKE ACTUATOR ASSEMBLY

Click here

9. REMOVE REAR DISC BRAKE CYLINDER ASSEMBLY

(a) Hold the 2 rear disc brake cylinder slide pins and remove the 2 bolts and rear disc brake cylinder assembly.

*a	Turn
*b	Hold

10. REMOVE REAR DISC BRAKE PAD

(a) Remove the 2 rear disc brake pads from the rear disc brake cylinder mounting.

11. REMOVE REAR DISC BRAKE ANTI-SQUEAL SHIM KIT

Click here

12. REMOVE REAR DISC BRAKE PAD SUPPORT PLATE

(a) Remove the 4 rear disc brake pad support plates from the rear disc brake cylinder mounting.

NOTICE:

Each rear disc brake pad support plate has a different shape. Be sure to put an identification mark on each rear disc brake pad support plate so that it can be reinstalled to its original position.

13. REMOVE REAR DISC BRAKE CYLINDER SLIDE PIN

(a) Remove the rear No. 1 disc brake cylinder slide pin and rear No. 2 disc brake cylinder slide pin from the rear disc brake cylinder mounting.

*1	Rear No. 1 Disc Brake Cylinder Slide Pin
*2	Rear No. 2 Disc Brake Cylinder Slide Pin

(b) Using a screwdriver with its tip wrapped with protective tape, remove the rear disc brake cylinder slide bushing from the rear No. 2 disc brake cylinder slide pin.

NOTICE:

Do not damage the rear No. 2 disc brake cylinder slide pin.

*a	Protective Tape

14. REMOVE REAR DISC BRAKE BUSHING DUST BOOT

(a) Remove the 2 rear disc brake bushing dust boots from the rear disc brake cylinder mounting.

15. REMOVE REAR DISC BRAKE CYLINDER MOUNTING

(a) Remove the 2 bolts and rear disc brake cylinder mounting.

16. REMOVE REAR DISC

(a) Put matchmarks on the rear disc and rear axle hub and bearing assembly.

Matchmark

(b) Remove the rear disc.

Rear Brake Flexible Hose

Rear Disc Brake Pad

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