AE92 Toyota Corolla Brake System

BR1
BRAKE SYSTEM
BRAKE SYSTEM
BR2
BRAKE SYSTEM
Precautions
PRECAUTIONS
1. Care must be taken to replace each part properly as it could
affect the performance of the brake system and result in
a driving hazard. Replace the parts with parts of the
same part number or equivalent.
2. It is very important to keep parts and the area clean when
repairing the brake system.
TROUBLESHOOTING
Possible cause
Problem
Low or spongy pedal
Brakes drag
Linings worn
Replace brake shoes or pads
Leak in brake system

Master cylinder faulty
Air in brake system
Wheel cylinder faulty
Piston seals worn or damaged
Rear brake automatic adjuster faulty
Repair leak
Repair or replace master cylinder
Bleed brake system
Repair wheel cylinder
Repair brake calipers
Repair or replace adjuster
Parking brake out of adjustment

Linkage binding
Booster push rod out of adjustment
Return spring faulty
Brake line restricted
Lining cracked or distorted
Adjust parking brake

Repair as necessary
Adjust push rod
Replace spring
Repair as necessary
Replace brake shoes and pads
Wheel cylinder or caliper piston sticking

Automatic adjuster broken
Repair as necessary
Master cylinder faulty

Brakes pull
Remedy
Tires improperly inflated

Oil or grease on linings
Brake shoes distorted, linings worn or
glazed
Brakes grab/chatter
BR16, 22,
30
BR9
BR7
BR22
BR16, 30
BR22
BR8
BR15
BR22
Replace adjuster
Repair or replace master cylinder
BR16, 22,
30
BR16, 22
30
BR22
BR9
Inflate tires to proper pressure

Check for cause/Replace shoes
Replace brake shoes
BR22
BR22
Replace drum or disc

Drum or disc out of round
Return spring faulty wheel cylinder faulty
Piston frozen in caliper
Disc brake pads sticking
Page
Replace spring
Repair caliper
Replace pads
BR16, 22,
30
BR22
BR22
BR16, 30
BR16, 30

Drum or disc scored or out of round

Replace drum or disc

glazed
Wheel cylinder faulty
Disc brake pads sticking
Brake booster faulty
Replace brake shoes
BR22
BR16, 22,
30
BR22

Replace pads
Repair booster
BR22
BR16, 30
BR14
BR3
BRAKE SYSTEM
Troubleshooting
TROUBLESHOOTING (Contd)
Problem
Hard pedal but
brakes inefficient
Snapping or clicking
noise when brakes are
applied
Scraping or grinding
noise when brakes are
applied
Possible cause
Remedy
Page

glazed, drums worn
Disc brake pads worn
Piston frozen in caliper
Brake booster faulty
Brake line restricted
Vacuum system leaking
Replace brake shoes

Replace pads
Repair caliper
Repair booster
Repair as necessary
Repair or replace
BR16, 30
BR16, 30
BR14
Drum brakesbrake shoes binding at

backing plate ledges
Drum brakesbacking plate ledges worn
Drum brakesloose or missing hold down
spring
Drum brakesloose set bolt at backing
plate
Disc brakesrust on front edge of inboard
pad
Disc brakesloose or missing pad support
plate
Disc brakesloose installation bolt
Disc brakeswear on slide bushing
Pad wear and pad wear indicator making
contact with the rotor
Lubricate
BR22
Replace and lubricate ledges

Replace or hook in
BR22
BR22
Tighten
BR22
Inspect, lubricate/Replace if
necessary
Replace or insert
BR16, 30
Tighten
Replace
Replace
BR16, 30
BR16,30
BR16, 30
Worn brake linings
Replace/Refinish drums or rotors if

heavily scored
Replace as required
BR16, 22,
30
BR16, 22,
30
Caliper to wheel or rotor interference

Dust cover to rotor or drum interference
Other brake system components:
Warped or bent brake backing plate or
splash shield, cracked drums or rotors
Tires rubbing against chassis and body
Pad wear and pad wear indicator making
contact with the rotor
BR16, 22,
30
BR22
BR16, 30
Correct or replace
Inspect and repair
BR16, 30
Inspect and repair

Replace
BR16, 30
BR4
BRAKE SYSTEM
Troubleshooting
Problem
Possible cause
Squealing, groaning or
chattering noise when brakes
are applied
NOTE: Brake friction
materials inherently generate
noise and heat in order to
dissipate energy.
As a result, occasional
squeal is normal and is
aggravated by severe
environmental conditions
such as cold, heat, wetness,
snow, salt, mud, etc.
This occasional
squeal is not a functional
problem and does not
indicate any loss of brake
effectiveness
Brake drums and linings, rotors and pads

worn or scored
Disc brakesmissing or damaged brake pad
antisqueal shim
Disc brakesburred or rusted calipers
Dirty, greased, contaminated or glazed
linings
Improper lining parts
Squealing noise when

brakes are not applied
Bent or warped backing plate causing

interference with drum
Improper machining of drum causing
interference with backing plate or shoe
Maladjustment of brake pedal or booster
push rod
Poor return of brake booster or master
cylinder or wheel cylinder
Disc brakesrusted, stuck
Other brake system components:
Loose or extra parts in brakes
Rear drum adjustment too tight causing
lining to glaze
worn, damaged or insufficiently lubricated
wheel bearings
Drum brakesweak, damaged or
incorrect shoe retracting springs
Drum brakesgrooved backing plate
ledges
Improper positioning of pads in caliper
Outside diameter of rotor rubbing caliper
housing
Housing installation of disc brake pad
support plate

push rod
Drum brakesweak damaged or incorrect
shoe holddown springs, loose or damaged
shoe holddown pins and springs and
grooved backing plate ledges
Remedy
Page
Inspect, repair or replace
BR16,30
Replace
Clean or deburr
Clean or replace
BR16, 30
Inspect and adjust
BR16,30
BR16, 22,
30
BR16, 22,
30
BR6, 15
BR22
Repair or replace
BR22
Replace drum
BR22
Inspect and adjust
BR6, 15

Inspect/Lubricate if necessary
Inspect, repair, replace as
required
BR9, 14,
16,22
BR16, 30
BR16, 22
30
SA8, 23,
31
BR22
Inspect and repair

Inspect, correct or replace
BR22
BR16, 30
BR16, 30
Correct
BR16, 30
Check for correct parts/Replace
BR5
BRAKE SYSTEM
Troubleshooting
Problem
Groaning, clicking or
ratting noise when
brakes are not
applied
Possible cause
Stones or foreign material trapped inside
wheel covers
Loose wheel nuts
Disc brakesfailure of shim
Disc brakeswear on slide bushing
Disc brakesloose installation bolt
push rod
Disc brakespoor return of piston
Drum brakesloose or extra parts
Worn, damaged or dry wheel bearings
Remedy
Page
Remove stones, etc.

Tighten to correct torque/Replace if
stud holes are elongated
Inspect/Replace if necessary
Inspect/Replace if necessary
Inspect/Tighten if necessary
Inspect and adjust
Inspect, remove or repair
Inspect, lubricate or replace
BR16, 30
BR16, 30
BR16, 30
BR6,15
BR16,30
BR22
SA8, 34,
42
BR6
BRAKE SYSTEM
Checks and Adjustments
CHECKS AND ADJUSTMENTS

CHECK AND ADJUSTMENT OF BRAKE
PEDAL
1. CHECK THAT PEDAL HEIGHT IS CORRECT, AS SHOWN
Pedal height from asphalt sheet:
139 149 mm (5.47 5.87 in.)
2. IF NECESSARY, ADJUST PEDAL HEIGHT
(a) Sufficiently loosen the stop light switch.
(b) Adjust the pedal height by turning the pedal push rod.
(c) Return the stop light switch until it lightly contacts the pedal
stopper.
(d) After adjusting the pedal height, check and adjust the pedal
freeplay.
3. CHECK THAT PEDAL FREEPLAY IS CORRECT, AS

SHOWN
(a) Stop the engine and depress the brake pedal several
times until there is no more vacuum left in the booster.
(b) Push in the pedal until the beginning of resistance is felt.
Measure the distance, as shown.
Pedal freeplay: 3 6 mm (0.12 0.24 in.)
HINT: The pedal freeplay is the amount of the stroke until
the booster air valve is moved by the pedal push rod.
4. IF NECESSARY, ADJUST PEDAL FREEPLAY
(a) If incorrect, adjust the pedal freeplay by turning the pedal push rod and tighten the clevis lock nut.
Torque: 260 kgcm (19 ftIb, 25 Nm)
(b) Start the engine and confirm that pedal freeplay exists.
(c) After adjusting the pedal freeplay, check the pedal
height.
5. CHECK THAT PEDAL RESERVE DISTANCE IS CORRECT,

AS SHOWN
Release the parking brake lever.
With engine running, depress the pedal and measure the
pedal reserve distance, as shown.
Pedal reserve distance from asphalt sheet at 50 kg (110.2
Ib, 490 N):
Rear drum brake type More than 55 mm (2.17 in.)
Rear disc brake type More than 60 mm (2.36 in.)
4WD More than 65 mm (256 in.)
If incorrect,troubleshoot the brake system.
BR7
BRAKE SYSTEM
OPERATIONAL TEST OF BRAKE

BOOSTER
HINT: If available, use a brake booster tester to check the
booster operating condition.
1. OPERATING CHECK
(a) Depress the brake pedal several times with the engine off,
and check that there is no change in the pedal reserve distance.
(b) Depress the brake pedal and start engine. If the pedal goes
down slightly, operation is normal.
2. AIR TIGHTNESS
(a) Start the engine and stop it after one or two minutes.
Depress the brake pedal several times slowly. If the pedal
goes down deepest the first time, but gradually rises after
the second or third time, the booster is air tight.
(b) Depress the brake pedal while the engine is running, and
stop the engine with the pedal depressed. If there is no
change in pedal reserve travel after holding the pedal for
thirty seconds, the booster is air tight.
BLEEDING OF BRAKE SYSTEM

HINT: If any work is done on the brake system or if air is suspected in the brake lines, bleed the system of air.
NOTICE: Do not let brake fluid remain on a painted surface. Wash
it off immediately.
1. FILL BRAKE RESERVOIR WITH BRAKE FLUID

Check the reservoir after bleeding each wheel. Add fluid, if
necessary.
2. BLEED MASTER CYLINDER

HINT: If the master cylinder was disassembled or if the
reservoir tank becomes empty, bleed the air from the
master cylinder.
(a) Disconnect the brake tubes from the master cylinder.
Use a container to catch the brake fluid.
(b) Slowly depress the brake pedal and hold it.
(c) Block off the outlet plug with your finger, and release the brake pedal.
(d) Repeat (b) and (c) three or four times.
(e) Connect the brake tubes to the master cylinder.
BR8
BRAKE SYSTEM
3. CONNECT VINYL TUBE TO WHEEL CYLINDER BLEEDER

PLUG
Insert other end of the tube in a halffull container of brake
fluid.
HINT: Begin air bleeding from the wheel cylinder with the longest hydraulic line.
4. BLEED BRAKE LINE
(a) Slowly pump the brake pedal several times.
(b) While an assistant depresses the pedal, loosen the bleeder
plug until fluid starts to run out. Then close the bleeder plug.
(c) Repeat this procedure until there are no more air bubbles in
the fluid.
Bleeder plug tightening torque: 85 kgcm
(74 in.Ib, 8.3 N m)
5. REPEAT PROCEDURE FOR EACH WHEEL
CHECK AND ADJUSTMENT OF PARKING

BRAKE
1. CHECK THAT PARKING BRAKE LEVER TRAVEL IS
CORRECT
Pull the parking brake lever all the way up, and count the number
of clicks.
Parking brake lever travel at 20 kg (44.1 Ib, 196 N )
Rear drum brake type 4 7 clicks
Rear disc brake type 5 8 clicks
2. IF NECESSARY, ADJUST PARKING BRAKE
HINT: Before adjusting the parking brake, make sure that the
rear brake shoe clearance has been adjusted.
For shoe clearance adjustment, see steps 8 and 9 on page
BR29 and step 9 on page BR39.
(a) Remove the console box.
(b) Loosen the lock nut and turn the adjusting nut until the travel is
correct.
(c) Tighten the lock nut and install the console box.
Torque: 55 kgcm (48 in.Ib, 5.4 Nm)
BR9
BRAKE SYSTEM
Master Cylinder
MASTER CYLINDER
REMOVAL OF MASTER CYLINDER
1. DISCONNECT LEVEL WARNING SWITCH

CONNECTOR
2. DRAW OUT FLUID WITH SYRINGE
NOTICE: Do not let brake fluid remain on a painted surface. Wash it
off immediately.
3. DISCONNECT BRAKE TUBES

Using SST, disconnect the brake tubes from the master cylinder.
SST 0975136011
4. REMOVE MASTER CYLINDER
Remove the mounting nuts and pull out the master cylinder and
gasket.
BR10
BRAKE SYSTEM
Master Cylinder
COMPONENTS
DISASSEMBLY OF MASTER
CYLINDER
1. REMOVE RESERVOIR
(a) Remove the set screw and pull out the reservoir.
(b) Remove the cap and strainer from the reservoir.
2. REMOVE TWO GROMMETS
3. PLACE CYLINDER IN VISE
4. REMOVE PISTON STOPPER BOLT

Using a screwdriver, push the pistons in all the way and
remove the piston stopper bolt and gasket.
HINT: Tape the screwdriver tip before use.
BR11
BRAKE SYSTEM
Master Cylinder
5. REMOVE TWO PISTONS AND SPRINGS

(a) Push in the piston with a screwdriver and remove the
snap ring with snap ring pliers.
(b) Remove the No. 1 piston and spring by hand, pulling
straight out, not at an angle.
(c) Place a rag and two wooden blocks on the work

table and lightly tap the cylinder flange against
the block edges until the No.2 piston drops out
of cylinder.
HINT: Make sure the distance (A) from the rag to
the top of the blocks is at least 100 mm (3.94 in.).
INSPECTION OF MASTER CYLINDER

COMPONENTS
HINT: Clean the disassembled parts with compressed air.
1. INSPECT MASTER CYLINDER BORE FOR RUST OR
SCORING
2. INSPECT CYLINDER FOR WEAR OR DAMAGE
If necessary, clean or replace the cylinder.
ASSEMBLY OF MASTER CYLINDER

(See page BR10)
1. APPLY LITHIUM SOAP BASE GLYCOL GREASE TO
RUBBER PARTS INDICATED BY ARROWS
2. INSTALL TWO SPRINGS AND PISTONS

NOTICE: Be careful not to damage the rubber lips on the
pistons.
(a) Insert the two springs and pistons straight in, not at an
angle.
NOTICE: If inserted at an angle, there is a possibility of
damaging the cylinder bore.
(b) Push in the piston with a screwdriver and install the

snap ring with snap ring pliers.
HINT: Tape the screwdriver tip before use.
NOTICE: Be careful not to scratch the cylinder bore.
BR12
BRAKE SYSTEM
Master Cylinder
3. INSTALL PISTON STOPPER BOLT

Using a screwdriver, push the piston in all the way and
install the piston stopper bolt over the gasket. Torque
the bolt.
4. INSTALL TWO GROMMETS
5. INSTALL RESERVOIR
(a) Install the cap and strainer to the reservoir.
(b) Push the reservoir onto the cylinder.
(c) Install the set screw while pushing on the reservoir.
Torque: 17.5 kgcm (15.2 in.Ib, 1.7 Nm)
NOTICE: Because the master cylinder and reservoir

tank union is a grommet type, the set screw is designed to not separate the reservoir from cylinder
and will not tighten down the reservoir. Therefore,
there is a clearance at point A. Do not insert washers
or an equivalent when tightening.
BR13
BRAKE SYSTEM
Master Cylinder
INSTALLATION OF MASTER
CYLINDER
(See page BR9)
1. CLEAN OUT GROOVE ON LOWER INSTALLATION
SURFACE OF MASTER CYLINDER
2. CONFIRM THAT UP MARK ON MASTER CYLINDER
BOOT IS IN CORRECT POSITION
3. ADJUST LENGTH OF BRAKE BOOSTER PUSH ROD

BEFORE INSTALLING MASTER CYLINDER
(See page BR15)
4. INSTALL MASTER CYLINDER

Install the master cylinder and gasket on the brake
booster with nuts and install 3way union.
5. CONNECT BRAKE TUBES

Using SST, connect the brake tubes to the master cylinder.
Torque the union nuts.
SST 0975136011
Torque: 155 kgcm (11 ftIb, 15 Nm )
6. CONNECT LEVEL WARNING SWITCH CONNECTOR

7. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND
BLEED BRAKE SYSTEM
(See page BR7)
8. CHECK FOR FLUID LEAKAGE
9. CHECK AND ADJUST BRAKE PEDAL
(See page BR6)
BR14
BRAKE SYSTEM
Brake Booster
BRAKE BOOSTER
REMOVAL OF BRAKE BOOSTER
1. REMOVE MASTER CYLINDER

(See page BR9)
2. DISCONNECT VACUUM HOSE FROM BRAKE
BOOSTER
3. REMOVE PEDAL RETURN SPRING
4. REMOVE CLIP AND CLEVIS PIN
5. REMOVE BRAKE BOOSTER, GASKET AND CLEVIS
BR15
BRAKE SYSTEM
Brake Booster
INSTALLATION OF BRAKE BOOSTER

(See page BR14)
1. ADJUST LENGTH OF BOOSTER PUSH ROD
(a) Install the gasket on the master cylinder.
(b) Set the SST on the gasket, and lower the pin until its
tip slightly touches the piston.
SST 0973700010
(c) Turn the SST upside down, and set it on the booster.
SST 0973700010
(d) Measure the clearance between the booster push rod and pin
head (SST).
Clearance: 0 mm (0 in.)
(e) Adjust the booster push rod length until the push rod lightly
touches the pin head.
2. INSTALL BRAKE BOOSTER, GASKET AND CLEVIS

(a) Install the booster and gasket.
(b) Install the clevis.
(c) Install and torque the booster mounting nuts.
3. CONNECT CLEVIS TO BRAKE PEDAL

Insert the clevis pin into the clevis through the brake
pedal and install the clip to the clevis pin.
4. INSTALL PEDAL RETURN SPRING
5. INSTALL MASTER CYLINDER AND 3WAY UNION
(See page BR13)
6. CONNECT HOSE TO BRAKE BOOSTER
BLEED BRAKE SYSTEM (See page BR7)
8. CHECK FLUID LEAKAGE
9. CHECK AND ADJUST BRAKE PEDAL
(See page BR6)
10. PERFORM OPERATIONAL CHECK
(See page BR7)
BR16
BRAKE SYSTEM
Front Brake
FRONT BRAKE
COMPONENTS
REPLACEMENT OF BRAKE PADS

HINT: If a squealing noise occurs from the brakes while
driving, check the pad wear indicator plate. If. the pad
wear indicator plate contacts the rotor disc, the brake
pads should be replaced.
1. REMOVE FRONT WHEEL
Remove the wheel and temporarily fasten the rotor disc
with the wheel nuts.
2. INSPECT PAD LINING THICKNESS

Check the pad thickness through the cylinder inspection hole and replace pads if not within specification.
Minimum thickness: 1.0 mm (0.039 in.)
BR17
BRAKE SYSTEM
Front Brake
3. REMOVE CYLINDER FROM TORQUE PLATE

(a) Remove the two installation bolts from the torque
plate.
(b) Remove the brake cylinder and suspend it so the
hose is not stretched.
HINT: Do not disconnect the brake hose.
4. REMOVE FOLLOWING PARTS
Two antisqueal springs
Two brake pads
Three antisqueal shims
A pad wear indicator plate
Four pad support plates

5. CHECK ROTOR DISC THICKNESS
(See step 2 on page BR20)
6. CHECK ROTOR DISC RUNOUT
7. INSTALL NEW PAD SUPPORT PLATES
Install the four pad support plates to the torque plate.
8. INSTALL NEW PADS

(a) Install a pad wear indicator plate to the inside pad.
HINT: Be sure the arrow on the pad wear indicator
plate is pointing in the direction of the rotor disc rotation.
(b) Install the antisqueal shims to the pads.
HINT: Apply disc brake grease to both side of the inner
antisqueal shim of the outside pad.
(c) Install the pads onto each support plate.

NOTICE: Do not allow oil or grease to get on the rubbing face.
(d) Install the antisqueal springs in position.
BR18
BRAKE SYSTEM
Front Brake
9. INSTALL CYLINDER
(a) Draw out a small amount of brake fluid from the reservoir.
(b) Press in the piston with a hammer handle or an equivalent.
HINT: Always change the pad on one wheel at a time as
there is possibility of the opposite piston flying out.
(c) Insert the brake cylinder carefully so the dust boot is not
wedged.
(d) Install and torque the two installation bolts.

10. INSTALL FRONT WHEEL

11. FILL BRAKE FLUID
REMOVAL OF CYLINDER
(See page BR16)
1. DISCONNECT BRAKE HOSE
Remove the union bolt and disconnect the flexible
hose.
Use a container to catch the brake fluid.
2. REMOVE BRAKE CYLINDER FROM TORQUE PLATE

Remove the two installation bolts and cylinder.
3. REMOVE PADS
BR19
BRAKE SYSTEM
Front Brake
DISASSEMBLY OF CYLINDER
(See page BR16)
1. REMOVE FOLLOWING PARTS
Two cylinder sliding bushings

Four dust boots
2. REMOVE CYLINDER BOOT SET RING AND BOOT

Using a screwdriver, remove the cylinder boot set ring
and remove the cylinder boot.
3. REMOVE PISTON FROM CYLINDER

(a) Put a piece of cloth or an equivalent between the piston
and cylinder.
(b) Use compressed air to remove the piston from the cylinder.
CAUTION: Do not place your fingers in front of the piston
when using compressed air.
4. REMOVE PISTON SEAL FROM BRAKE CYLINDER

Using a screwdriver, remove the piston seal.
BR20
BRAKE SYSTEM
Front Brake
INSPECTION AND REPAIR OF FRONT BRAKE

COMPONENTS
1. MEASURE PAD LINING THICKNESS
Standard thickness: 10.0 mm (0.394 in.)
Replace the pad if the thickness is less than the minimum or if it
shows sign of uneven wear.
2. MEASURE ROTOR DISC THICKNESS

Standard thickness:
4AGE Engine 22.0 mm (0.866 in.)
4AFE Engine 18.0 mm (0.709 in.)
Minimum thickness:
4AGE Engine 21.0 mm (0.827 in.)
4AFE Engine 17.0 mm (0.669 in.)
If the disc is scored or worn, or if thickness is less
than minimum, repair or replace the disc.
3. MEASURE ROTOR DISC RUNOUT
HINT: Before measuring the runout, confirm that the
front hub bearing play is within specification.
Measure the rotor disc runout at 10 mm (0.39 in.) from
the outer edge of the rotor disc.
Maximum disc runout: 0.09 mm (0.0035 in.)
If the runout is greater than the maximum, inspect and
adjust it following the procedure below:
Then replace the disc if necessary.
(a) Remove the torque plate from the knuckle.
(b) Remove the hub nuts of the temporarily installed disc
and pull off the rotor disc.
(c) Check that the hub axial play is within specification,
and replace the bearing if not within specification.
(d) Install the rotor disc and measure the disc runout,
then shift the rotor disc one fourth of a turn and
measure the disc runout. Similarly measure the
runout at each position, and select the position
where the runout is minimum.
(e) In this position, if the runout is within specification, install the torque plate and torque the
mounting bolts.
(f) If not within specification, replace the rotor disc,

and repeat (d) and (e).
BR21
BRAKE SYSTEM
Front Brake
ASSEMBLY OF CYLINDER
(See page BR16)
PARTS INDICATED BY ARROWS
2. INSTALL PISTON SEAL AND PISTON IN CYLINDER
3. INSTALL CYLINDER BOOT AND SET RING IN
CYLINDER
4. INSTALL DUST BOOTS AND CYLINDER SLIDING

BUSHING
(a) Install the four dust boots to the brake cylinder.
(b) Insure that the boots are secured firmly to each brake cylinder groove.
(c) Install the sliding bushings into the boots.
(d) Insure that the boots are secured firmly to each, bushing
groove.
INSTALLATION OF CYLINDER
(See page BR16)
1. INSTALL PADS
(See step 7 and 8 on page BR17)
2. INSTALL CYLINDER
3. CONNECT FLEXIBLE HOSE

Set the flexible hose and new gaskets in position and
install the union bolt.

BR22
BRAKE SYSTEM
Rear Brake
REAR BRAKE
Drum Brake
COMPONENTS
BR23
BRAKE SYSTEM
Rear Brake
REMOVAL OF REAR BRAKE

1. INSPECT SHOE LINING THICKNESS
Remove the inspection hole plug, and check the shoe
lining thickness through the hole.
If less than minimum, replace the shoes.
2. REMOVE REAR WHEEL
3. REMOVE BRAKE DRUM

If the brake drum cannot be removed easily, perform
the following steps.
(a) Insert a screwdriver through the hole in the backing
plate, and hold the automatic adjusting lever away
from the adjuster.
(b) Using another screwdriver, reduce the brake shoe adjustment by turning the adjusting bolt.
4. REMOVE FRONT SHOE

(a) Using SST, remove the return spring.
SST 0970330010
Using SST, remove the shoe holddown spring, two
cups and pin from the front shoe.
SST 0971800010
(c) Disconnect the anchor spring from the front shoe and
remove the front shoe.
(d) Remove the anchor spring from the rear shoe.
5. REMOVE ADJUSTER AND REAR SHOE
(a) Using SST, remove the shoe holddown spring, two
cups and pin from the rear shoe.
SST 09718 10
(b) Using pliers, remove the adjusting lever spring.
(c) Remove the adjuster together with the return spring.

(d) Using pliers, disconnect the parking brake cable from
the lever and remove the rear shoe.
BR24
BRAKE SYSTEM
Rear Brake
6. DISCONNECT BRAKE TUBE FROM WHEEL

CYLINDER
Using SST, disconnect the brake tube. Use a container
to catch the brake fluid.
SST 0975136011
7. REMOVE WHEEL CYLINDER

Remove the two bolts and wheel cylinder.
8. REMOVE FOLLOWING PARTS FROM WHEEL

CYLINDER
(a) Two boots
(b) Two pistons
(c) Two piston cups
(d) Spring
INSPECTION AND REPAIR OF REAR BRAKE

COMPONENTS
1. INSPECT DISASSEMBLED PARTS
Inspect the disassembled parts for wear, rust or damage.
2. INSPECT BRAKE SHOE LINING THICKNESS

If the shoe lining is less than minimum or shows signs
of uneven wear, replace the brake shoes.
HINT: If any of the brake shoes have to be replaced,
replace all of the rear brake shoes in order to maintain
even braking.
BR25
BRAKE SYSTEM
Rear Brake
3. INSPECT BRAKE DRUM INSIDE DIAMETER

Standard inside diameter: 200.0 mm (7.874 in.)
Maximum inside diameter: 201.0 mm (7.913 in.)
If the drum is scored or worn, the brake drum may be
lathed to the maximum inside diameter.
4. INSPECT BRAKE LINING AND DRUM FOR PROPER

CONTACT
If the contact between the brake lining and drum is improper, repair the lining with a brake shoe grinder, or
replace the brake shoe assembly.
5. MEASURE CLEARANCE BETWEEN BRAKE SHOE

AND LEVER
Using a feeler gauge, measure the clearance.
Standard clearance: Less than 0.35 mm (0.0138 in.)
If the clearance is not within specification, replace the
shim with one of the correct size.
Shim thickness
6. IF NECESSARY, REPLACE SHIM

(a) Remove the parking brake shoe lever, and install the
correct size shim.
(b) Install the parking brake shoe lever with a new

Cwasher.
(c) Remeasure the clearance.
BR26
BRAKE SYSTEM
Rear Brake
INSTALLATION OF REAR BRAKE

(See page BR22)
HINT: Assemble the parts in the correct direction as shown.

FOLLOWING PARTS
(a) Two piston cups
(b) Two pistons
BR27
BRAKE SYSTEM
Rear Brake
2. ASSEMBLE WHEEL CYLINDER

(a) Install two piston cups to the pistons.
(b) Install the spring and two pistons into the wheel cylinder. Check that the flanges of the piston are pointed
inward.
(c) Install two boots.
3. INSTALL WHEEL CYLINDER

Install the wheel cylinder on the backing plate with the
two bolts.
4. CONNECT BRAKE TUBE TO WHEEL CYLINDER

Using SST, connect the brake tube.
SST 0975136011
5. APPLY HIGH TEMPERATURE GREASE TO

FOLLOWING PARTS
(a) Backing plate and brake shoe contact points
(b) Anchor plate and brake shoe contact points
(c) Adjusting bolt

(d)Adjuster and brake shoe contact
points
BR28
BRAKE SYSTEM
Rear Brake
6. INSTALL ADJUSTER AND REAR SHOE

(a) Using pliers, connect the parking brake cable to the lever.
(b) Set the adjuster and return spring.
(c) Install the adjusting lever spring.

(d) Set the rear shoe in place with the end of the shoe inserted in the wheel cylinder and the other end in the
anchor plate.
NOTICE: Do not allow oil or grease to get on the rubbing
face.
(e) Using SST, install the shoe holddown spring, two

cups and pin. SST 0971800010
7. INSTALL FRONT SHOE
(a) Install the anchor spring between the front and rear
shoes.
(b) Set the front shoe in place with the end of the shoe inserted in the wheel cylinder and the adjuster in place.
face.
(c) Using SST, install the shoe holddown spring, two cups
and pin.
SST 0971800010
(d) Using SST, connect the return spring.
SST 0970330010
BR29
BRAKE SYSTEM
Rear Brake
8. CHECK OPERATION OF AUTOMATIC ADJUSTING

MECHANISM
(a) Move the parking brake lever of the rear shoe back
and forth, as shown. Check that the adjusting bolt
turns.
If the adjusting bolt does not turn, check for incorrect
installation of the rear brakes.
(b) Adjust the adjuster length to the shortest possible

amount.
(c) Install the drum.
(d) Pull the parking brake lever all the way up until a clicking
sound can no longer be heard.
9. CHECK CLEARANCE BETWEEN BRAKE SHOES AND

DRUM
(a) Remove the drum.
(b) Measure the brake drum inside diameter and diameter
of the brake shoes. Check that the difference between the diameters is the correct shoe clearance.
Shoe clearance: 0.6 mm (0.024 in.)
If incorrect, check the parking brake system.
10. INSTALL BRAKE DRUM AND REAR WHEEL

BLEED BRAKE SYSTEM
BR30
BRAKE SYSTEM
Rear Brake
Disc Brake
COMPONENTS
REPLACEMENT OF BRAKE PADS

HINT: If a squealing noise occurs from the rear brakes
while driving, check the pad wear indicator plate. If
there are traces of the indicator plate contacting the
rotor disc, the brake pad should be replaced.
1. REMOVE REAR WHEEL
Remove the wheel and temporarily fasten the rotor
disc with the hub nuts.
2. INSPECT PAD LINING THICKNESS

Check the pad thickness through the cylinder inspection hole and replace pads if not within specification.
BR31
BRAKE SYSTEM
Rear Brake
3. REMOVE CYLINDER FROM TORQUE PLATE

(a) Remove the installation bolt from the torque plate.
(b) Remove the brake cylinder and suspend it so the hose
is not stretched.
HINT: Do not remove the cylinder from the main pin,
and do not disconnect the brake hose.
4. REMOVE FOLLOWING PARTS:
Two
Two
Two
Two
brake pads
antisqueal shims
antirattle springs
pad guide plates
5. INSTALL PAD GUIDE PLATES AND ANTIRATTLE

SPRINGS
6. INSTALL NEW PADS AND ANTISQUEAL SHIMS

(a) Install the antisqueal shims to the pads.
(b) Raise the cylinder, and install the pads to the torque
plate.
HINT: Install the pads so the wear indicator is at the top
side.
face.
7. LOWER CYLINDER
(a) Using SST, slowly turn the piston clockwise while
pushing it into where it locks.
SST 0971914020 (0971900020)
BR32
BRAKE SYSTEM
Rear Brake
(b) Fit the pad protrusion into the piston stopper

groove, and install the cylinder.
HINT: Insert the cylinder carefully so the boot is
not wedged.
8. INSTALL CYLINDER INSTALLATION BOLT

Install and torque the cylinder installation bolt.
Torque: 200 kgcm (14 ftIb, 20 N m )
9. INSTALL REAR WHEEL

10. CHECK THAT FLUID LEVEL IS AT MAX LINE
11. ADJUST PARKING BRAKE AUTOMATIC ADJUSTER
BY DEPRESSING BRAKE PEDAL SEVERAL TIMES
REMOVAL OF CYLINDER
(See page BR26)
1. DISCONNECT BRAKE HOSE FROM CYLINDER
(a) Remove the union bolt and two gaskets, and disconnect the brake hose.
(b) Use a container to catch the brake fluid.
2. DISCONNECT PARKING BRAKE CABLE FROM CYLINDER
3. REMOVE CYLINDER
Remove the installation bolt and cylinder.
DISASSEMBLY OF CYLINDER
(See page BR30)
1. REMOVE SLIDING BUSHING AND BOOT
2. REMOVE MAIN PIN BOOT
3. REMOVE CYLINDER BOOT SET RING AND CYLINDER
BOOT
BR33
BRAKE SYSTEM
Rear Brake
4. REMOVE PISTON FROM CYLINDER

Using SST, turn piston counterclockwise and remove it.
SST 0971914020 (0971900020)
5. REMOVE PISTON SEAL FROM CYLINDER
6. REMOVE SNAP RING FROM CYLINDER

(a) Set SST onto the adjusting bolt, and lightly tighten it
with a 14 mm socket.
SST 0975600010
NOTICE:
To insure safety, always use SST as there is a possibility of the spring flying out, causing injury or damage to the interior surface of the cylinder.
Be careful not to tighten the SST too tightly as this

may damage the spring retainer.
(b) Using snap ring pliers, remove the snap ring from the
cylinder.
7. REMOVE ADJUSTING BOLT

From the cylinder, pull out the spring retainer, spring,
spring plate and stopper together with the adjusting
bolt.
NOTICE:
Be careful not to pry too hard.
Be careful not to damage the Oring.
8. DISASSEMBLE ADJUSTING BOLT

(a) Remove SST.
SST 0975600010
(b) Remove the spring retainer, spring, spring plate and
stopper from the adjusting bolt.
(c) Remove the Oring from the adjusting bolt.
9. REMOVE PARKING BRAKE STRUT
10. REMOVE CABLE SUPPORT BRACKET
BR34
BRAKE SYSTEM
Rear Brake
11. REMOVE TORSION SPRING FROM PARKING BRAKE

CRANK
12. REMOVE PARKING BRAKE CRANK FROM CYLINDER
13. REMOVE PARKING BRAKE CRANK BOOT

Using a screwdriver, lightly tap on the metal portion of
the boot and remove it.
HINT: Do not remove the boot unless replacing it.
14. REMOVE STOPPER PIN
INSPECTION AND REPAIR OF REAR BRAKE

COMPONENTS
1. MEASURE PAD LINING THICKNESS
Replace the pad if the thickness is less than the minimum or if it
shows sign of uneven wear.
2. MEASURE ROTOR DISC THICKNESS

If the disc is scored or worn, if thickness is less than
minimum, repair or replace the disc.
3. MEASURE ROTOR DISC RUNOUT

Measure the rotor disc runout at 10 mm (0.39 in.) from
the outer edge of the rotor disc.
Maximum disc runout: 0.10 mm (0.0039 in.)
If the runout is greater than the maximum, replace the
disc.
BR35
BRAKE SYSTEM
Rear Brake
4. IF NECESSARY, REPLACE ROTOR DISC

(a) Remove the torque plate from the rear axle carrier.
(b) Remove the hub nuts and rotor disc.
(c) Install a new rotor disc and temporarily fasten the hub nuts.
(d) Install the torque plate to the rear axle carrier.
ASSEMBLY OF CYLINDER
(See page BR30)
PARTS INDICATED BY ARROWS
HINT: Pack the lithium soap base glycol grease into
areas marked A.
2. INSTALL STOPPER PIN

Tap in the pin to the brake cylinder until the stopper pin
extends 25 mm (0.98 in.).
BR36
BRAKE SYSTEM
Rear Brake
3. INSTALL PARKING BRAKE CRANK BOOT IN CYLINDER

Using a 24 mm socket wrench, tap in the boot to the
cylinder.
4. INSTALL PARKING BRAKE CRANK IN CYLINDER

NOTICE: Securely match the crank boot with the groove
of the crank seal.
5. INSTALL CABLE SUPPORT BRACKET

(a) Press the surface of the support bracket flush against the
cylinder wall and tighten the bolt.
Torque: 475 kgcm (34 ftib, 47 Nm)
(b) Check that the clearance between the parking brake crank
and cable support bracket is 0.6 mm (0.236 in.).
6. INSTALL TORSION SPRING

Install the torsion spring and check that the parking brake
crank subassembly is in touch with the stopper pin.
7. INSTALL PARKING BRAKE STRUT

Before installing the strut, adjust the rollers of the needle roller
bearing so they do not catch on the cylinder hole.
Then install the strut to the cylinder.
8. INSTALL A NEW ORING TO ADJUSTING BOLT
BR37
BRAKE SYSTEM
Rear Brake
9. ASSEMBLE ADJUSTING BOLT

(a) Assemble the stopper, plate, spring and spring retainer to the adjusting bolt, and using SST, fully tighten
them down by hand.
SST 0975600010
NOTICE:
Position the inscribed surface of the stopper upward.
Align the notches of the spring retainer with the

notches of the stopper.
(b) Install the adjusting bolt subassembly into the cylinder.
10. INSTALL SNAP RING

(a) Using snap ring pliers, install the snap ring.
HINT: Face the snap ring opening toward the bleeder side.
(b) Remove SST.
SST 0975600010
(c) Firmly pull up the adjusting bolt by hand and insure that it
does not move.
11. PERFORM OPERATIONAL CHECK

After performing steps 1 to 10, move the parking brake
crank by hand and insure that the adjusting bolt
moves smoothly.
12. INSTALL PISTON SEAL IN CYLINDER
13. ASSEMBLE PISTON IN CYLINDER

(a) Using SST, slowly screw in the piston clockwise until
it will not descend any further.
SST 0971914020 (0971900020)
BR38
BRAKE SYSTEM
Rear Brake
(b) Align the center of the piston stopper groove with the
positioning protrusion of the cylinder.
14. INSTALL CYLINDER BOOT IN CYLINDER
15. INSTALL SET RING IN CYLINDER
16. INSTALL MAIN PIN BOOT
17. INSTALL DUST BOOT AND SLIDING BUSHING

(a) Install the dust boot.
HINT: Be careful that the seal does not fold under.
(b) Install the bushing into the boot.
INSTALLATION OF CYLINDER
(See page BR30)
1. INSTALL ANTIRATTLE SPRINGS AND PAD GUIDE
PLATES
2. INSTALL PADS AND ANTISQUEAL SHIMS
3. INSTALL CYLINDER ONTO MAIN PIN

Install the cylinder onto the main pin.
HINT: Make sure that the boot end is installed into the
groove of the main pin.
4. CONNECT PARKING BRAKE CABLE
5. INSTALL CYLINDER
(a) Fit the pad protrusion into the piston stopper groove,
and install the cylinder.
HINT: Insert the cylinder carefully so the boot is not
wedged.
BR39
BRAKE SYSTEM
Rear Brake
(b) Install the cylinder installation bolt and torque the

bolt.
(c) Install the parking brake cable clip.
6. CONNECT BRAKE HOSE

Install the brake hose in position, and tighten the union
bolt through new gaskets.

9. ADJUST PARKING BRAKE LEVER TRAVEL

(a) Pull up the parking brake lever for a few times.
(b) Release the parking brake lever.
(c) Depress the brake pedal several times and adjust the
rear brake automatically.
(d) Check that the parking brake crank touches the stopper pin.
(e) Pull the parking brake lever all the way up, and count the
number of clicks.
Parking brake lever travel at 20 kg (44.1 Ib, 196N):
5 8 clicks
(f) If necessary, adjust parking brake lever travel.
(See page BR8)
BR40
BRAKE SYSTEM
Proportioning Valve
PROPORTIONING VALVE (P VALVE)

CHECK OF FLUID PRESSURE
1. CONNECT FLUID PRESSURE GAUGE TO P VALVE
2. BLEED AIR FROM FLUID PRESSURE GAUGE

3. RAISE MASTER CYLINDER PRESSURE AND CHECK REAR
WHEEL CYLINDER PRESSURE
Specifications
Master cylinder pressure
Rear wheel cylinder pressure
4AG E
4AFE
If the rear wheel cylinder pressure is incorrect, replace

the P valve assembly.
4. BLEED BRAKE SYSTEM
5. CHECK FLUID LEAKAGE

AE92 Toyota Corolla Brake System

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AE92 Toyota Corolla Brake System

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BR1

Replace brake shoes or pads

Leak in brake system

Parking brake out of adjustment

Adjust parking brake

Wheel cylinder or caliper piston sticking

Master cylinder faulty

Tires improperly inflated

Inflate tires to proper pressure

Replace drum or disc

Oil or grease on linings

Check for cause/Replace shoes

Brake shoes distorted, linings worn or

Replace brake shoes

Repair wheel cylinder

Oil or grease on linings

Check for cause/Replace shoes

Brake shoes distorted, linings worn or

Replace brake shoes

Drum brakesbrake shoes binding at

Replace and lubricate ledges

Worn brake linings

Replace/Refinish drums or rotors if

Caliper to wheel or rotor interference

Inspect and repair

Brake drums and linings, rotors and pads

Squealing noise when

Bent or warped backing plate causing

Maladjustment of brake pedal or booster

Inspect, repair or replace

Inspect and adjust

Inspect, repair or replace

Inspect and adjust

Inspect, repair or replace

Inspect, repair or replace

Inspect and repair

Check for correct parts/Replace

Remove stones, etc.

Checks and Adjustments

CHECKS AND ADJUSTMENTS

3. CHECK THAT PEDAL FREEPLAY IS CORRECT, AS

5. CHECK THAT PEDAL RESERVE DISTANCE IS CORRECT,

Checks and Adjustments

OPERATIONAL TEST OF BRAKE

BLEEDING OF BRAKE SYSTEM

1. FILL BRAKE RESERVOIR WITH BRAKE FLUID

2. BLEED MASTER CYLINDER

Checks and Adjustments

3. CONNECT VINYL TUBE TO WHEEL CYLINDER BLEEDER

CHECK AND ADJUSTMENT OF PARKING

1. DISCONNECT LEVEL WARNING SWITCH

3. DISCONNECT BRAKE TUBES

4. REMOVE PISTON STOPPER BOLT

5. REMOVE TWO PISTONS AND SPRINGS

(c) Place a rag and two wooden blocks on the work

INSPECTION OF MASTER CYLINDER

ASSEMBLY OF MASTER CYLINDER

2. INSTALL TWO SPRINGS AND PISTONS

(b) Push in the piston with a screwdriver and install the

3. INSTALL PISTON STOPPER BOLT

4. INSTALL TWO GROMMETS

NOTICE: Because the master cylinder and reservoir

3. ADJUST LENGTH OF BRAKE BOOSTER PUSH ROD

4. INSTALL MASTER CYLINDER