Toyota Highlander 6 2001-06

Parking Brake Shoes 1

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Adjustment



  1. Raise and safely support the vehicle.
  2.  
  3. Remove the rear wheel and tire assemblies.
  4.  
  5. Adjust parking brake shoe clearance, as follows:
    1. Unbolt and remove the caliper (do not disconnect the fluid line) and the rotor)
    2.  
    3. Temporarily install the hub nuts.
    4.  
    5. Remove the hole plug, and turn the adjuster and expand the shoes until the disc locks.
    6.  
    7. Contract the shoe adjuster until the disc can rotate smoothly. Standard : Return 8 notches
    8.  
    9. Check to make sure there is no brake drag.
    10.  
    11. Install the hole plug.

      Click image to see an enlarged view

      Fig. Adjusting the brake shoe clearance

    12.  

  6.  
  7. Install the rotor and caliper.
  8.  
  9. Install the rear wheel and tire assembly and tighten the lug nuts to 76 ft. lbs. (103 Nm).
  10.  
  11. Check the parking brake pedal travel:
    1. Slowly depress the parking brake pedal all the way, and count the number of clicks. With a force of 66 lbs. (294 N), then parking brake should be between 5-7 clicks.

      Click image to see an enlarged view

      Fig. When you depress the parking brake pedal completely, it should click 5-7 times. If not, you need to adjust the travel

    2.  

  12.  
  13. If necessary, adjust the parking brake travel, as follows:
    1. Confirm that the parking brake pedal is released.
    2.  
    3. Fix the turn buckle and loosen the lock nut -A-.
    4.  
    5. Rotate the turn buckle to adjust the parking brake pedal travel to the specification.
    6.  
    7. Fix the turn buckle and tighten the lock nut -A- to 44 inch lbs. (5 Nm).
    8.  
    9. After operating the parking brake several times, check the parking brake pedal travel.
      NOTE
      If adjustment cannot be done by loosening the nut -A-, adjust the travel by loosening the nut -B-. The tightening torque for nut B is 9 ft. lbs. (12.5 Nm).

    10.  
    11. Check whether parking brake drags or not.
    12.  
    13. When operating the parking brake pedal, check that the parking brake pedal indicator light lights up.

      Click image to see an enlarged view

      Fig. Location of the turn buckle and locknuts A and B for parking brake adjustment

    14.  

  14.  

  1. Raise and safely support the vehicle.
  2.  
  3. Remove the rear wheel and tire assemblies.
  4.  
  5. Adjust parking brake shoe clearance, as follows:
    1. Temporarily install the hub nuts.
    2.  
    3. Remove the hole plug, turn the adjuster and expand the shoes until the disc locks.
    4.  
    5. Contract the shoe adjuster until the disc rotates smoothly. Standard : return 8 notches
    6.  
    7. Check that the shoe has no brake drag.
    8.  
    9. Install the hole plug.

      Click image to see an enlarged view

      Fig. Adjusting the brake shoe clearance

    10.  

  6.  
  7. Install the rotor and caliper.
  8.  
  9. Install the rear wheel and tire assembly and tighten the lug nuts to 76 ft. lbs. (103 Nm).
  10.  
  11. Inspect the parking brake pedal travel, as follows:
    1. Firmly step on the parking brake pedal.
    2.  
    3. release the parking brake.
    4.  
    5. Once more, slowly depress the parking brake pedal all the way, and count the number of clicks. The parking brake pedal should travel 5 to 7 clicks at 67 lbs. (300 N).
    6.  

  12.  
  13. If necessary, adjust parking brake pedal travel, as follows:
    1. Remove the lower instrument panel finish panel sub-assembly.
    2.  
    3. Remove the lower instrument panel insert sub- assembly.
    4.  
    5. Depress the parking brake pedal 5 clicks to make room for the procedure, and loosen the lock nut with fixing adjusting nut by wrench.
    6.  
    7. Release the parking brake pedal to the original position.
    8.  
    9. Turn the parking brake wire adjusting nut until the parking brake pedal travel is correct.
    10.  
    11. Use a wrench to hold the parking brake adjusting nut, then tighten the lock nut to 53 inch lbs. (6 Nm).

      Click image to see an enlarged view

      Fig. Use a wrench to hold the parking brake adjusting nut secure while tightening the lock nut

    12.  
    13. Count the number of clicks after depressing and canceling the parking brake pedal 3 to 4 times.
    14.  
    15. Check whether the parking brake drags or not.
    16.  
    17. When operating the parking brake pedal, check that the parking brake pedal indicator light is lit.
    18.  

  14.  

Highlander Hybrid
  1. Raise and safely support the vehicle.
  2.  
  3. Remove the rear wheel and tire assemblies.
  4.  
  5. Adjust parking brake shoe clearance, as follows:
    1. Temporarily install the hub nuts.
    2.  
    3. Remove the hole plug, turn the adjuster and expand the shoes until the disc locks.
    4.  
    5. Contract the shoe adjuster until the disc rotates smoothly. Standard : return 8 notches
    6.  
    7. Check that the shoe has no brake drag.
    8.  
    9. Install the hole plug.

      Click image to see an enlarged view

      Fig. Adjusting the brake shoe clearance

    10.  

  6.  
  7. Install the rotor and caliper.
  8.  
  9. Install the rear wheel and tire assembly and tighten the lug nuts to 76 ft. lbs. (103 Nm).
  10.  
  11. Inspect the parking brake pedal travel, as follows:
    1. Firmly step on the parking brake pedal.
    2.  
    3. release the parking brake.
    4.  
    5. Once more, slowly depress the parking brake pedal all the way, and count the number of clicks. The parking brake pedal should travel 5 to 7 clicks at 67 lbs. (300 N).
    6.  

  12.  
  13. If necessary, adjust parking brake pedal travel, as follows:
    1. Remove the lower instrument panel finish panel sub-assembly.
    2.  
    3. Remove the lower instrument panel insert sub- assembly.
    4.  
    5. Depress the parking brake pedal 5 clicks to make room for the procedure, and loosen the lock nut with fixing adjusting nut by wrench.
    6.  
    7. Release the parking brake pedal to the original position.
    8.  
    9. Turn the parking brake wire adjusting nut until the parking brake pedal travel is correct.
    10.  
    11. Use a wrench to hold the parking brake adjusting nut, then tighten the lock nut to 53 inch lbs. (6 Nm).

      Click image to see an enlarged view

      Fig. Use a wrench to hold the parking brake adjusting nut secure while tightening the lock nut

    12.  
    13. Count the number of clicks after depressing and canceling the parking brake pedal 3 to 4 times.
    14.  
    15. Check whether the parking brake drags or not.
    16.  
    17. When operating the parking brake pedal, check that the parking brake pedal indicator light is lit.
    18.  

  14.  

Removal & Installation



  1. Raise and safely support the vehicle.
  2.  
  3. Remove the rear wheel and tire assemblies.
  4.  
  5. Unbolt and remove the rear caliper, but do not disconnect the fluid line. Suspend the caliper out of the way with a piece of wire.
  6.  
  7. Matchmark the brake disc (rotor) to the axle hub.
  8.  
  9. Make sure the parking brake is fully released, then remove the rear brake disc (rotor).
    NOTE
    If the rotor cannot be easily removed, turn the shoe adjuster until the wheel turns freely.



    Click image to see an enlarged view

    Fig. If you have difficulty removing the rotor, turn the shoe adjuster until the wheel turns freely

  10.  
  11. Inspect the brake disc (rotor) inside diameter, as follows:
    1. Using a brake drum gauge or equivalent, measure the inside diameter of the disc and compare with the following: Standard inside diameter: 170 mm (6.69 in.). Maximum inside diameter: 171 mm (6.73 in.)

      Click image to see an enlarged view

      Fig. Use a brake drum gauge to measure the inside of the disc

    2.  

  12.  
  13. Use needle-nose pliers to remove the 2 parking brake return tension springs.

    Click image to see an enlarged view

    Fig. Use a needle-nose pliers to remove the 2 return tension springs (shown by arrows)

  14.  
  15. Slide out the parking brake front shoe and remove the compression spring.
  16.  
  17. Remove the parking brake shoe strut.
  18.  
  19. Remove the parking brake shoe, as follows:
    1. Release the cup claw and remove the front and rear parking brake shoe.
    2.  
    3. Disconnect the parking brake cable from the shoe lever.
    4.  
    5. Remove the tension spring and shoe adjuster screw set from the front and rear shoe.
    6.  
    7. Remove the 2 shoe hold-down springs, 4 cups and 2 pins.
    8.  
    9. Using a screwdriver, remove the C-washer.
    10.  
    11. Remove the shim and shoe lever from the parking brake shoe.

      Click image to see an enlarged view

      Fig. Removing the parking brake shoes



      Click image to see an enlarged view

      Fig. Use a screwdriver to remove the C-washer

    12.  

  20.  
  21. Check the parking brake shoe lining thickness, as follows:
    1. Using a ruler, measure the thickness of the shoe lining. Standard thickness is 2.0 mm (0.079 in.). Minimum thickness is 1.0 mm (0.039 in.). If the lining thickness is at the minimum thickness or less, or if there is severe, uneven wear, replace the brake shoe.
    2.  

  22.  
  23. Inspect brake disc and parking brake shoe lining for proper contact, as follows:
    1. Apply chalk to the inside surface of the disc, then grind down the brake shoe lining to fit. If the contact between the brake disc and the shoe lining is improper, repair it using a brake shoe grinder or replace the brake shoe assembly.
    2.  

  24.  
  25. Apply the high temperature grease to the shoe attached surface of backing plate

    Click image to see an enlarged view

    Fig. Exploded view of the parking brake and related components-2001-03 models

  26.  

To install: .

  1. Install the parking brake shoe, as follows: (a) Install the shoe lever and shim to the rear shoe with a new C-washer . (b) Using a feeler gauge, measure the clearance. Standard clearance: Less than 0.35 mm (0.0138 in.) If the clearance is not within the specification, replace the shim with one of the correct size. Shim size: 0.3 mm (0.012 in.), 0.9 mm (0.035 in.) or 0.6 mm (0.024 in.).

    Click image to see an enlarged view

    Fig. Use a feeler gauge to measure the clearance as shown

    1. Apply the high temperature grease to the adjusting bolt.

      Click image to see an enlarged view

      Fig. Apply the high temperature grease to the adjusting bolt

    2.  
    3. Install the shoe adjusting screw set and tension spring to the front and rear shoe.
    4.  
    5. Install the 2 pins, 4 cups and 2 shoe hold-down springs.
    6.  
    7. Connect the parking brake cable to the shoe lever.
    8.  
    9. Install the front and rear parking brake shoe.
    10.  

  2.  
  3. Install the parking brake shoe strut.
  4.  
  5. Install the parking brake shoe strut compression spring.
  6.  
  7. Use needle nose pliers to install the 2 return tension springs.
  8.  
  9. Check that each parking brake component is installed properly.
    WARNING
    There should be no oil or grease adhering to the friction surface of the shoe lining and disc.



    Click image to see an enlarged view

    Fig. Make sure all of the parking brake components are properly installed

  10.  
  11. Install the brake disc (rotor).
  12.  
  13. Adjust parking brake shoe clearance, as follows:
    1. Temporarily install the hub nuts.
    2.  
    3. Remove the hole plug, and turn the adjuster and expand the shoes until the disc locks.
    4.  
    5. Contract the shoe adjuster until the disc can rotate smoothly. Standard : Return 8 notches
    6.  
    7. Check to make sure there is no brake drag.
    8.  
    9. Install the hole plug.

      Click image to see an enlarged view

      Fig. Adjusting the brake shoe clearance

    10.  

  14.  
  15. Install the caliper, as outlined earlier in this section.
  16.  
  17. Install the rear wheel and tire assembly and tighten the lug nuts to 76 ft. lbs. (103 Nm).
  18.  
  19. Adjust the parking brake pedal travel, as outlined in this section.
  20.  

  1. Raise and safely support the vehicle.
  2.  
  3. Remove the rear wheel and tire assemblies.
  4.  
  5. Unbolt and remove the rear caliper, but do not disconnect the fluid line. Suspend the caliper out of the way with a piece of wire.
  6.  
  7. Matchmark the brake disc (rotor) to the axle hub.
  8.  
  9. Make sure the parking brake is fully released, then remove the rear brake disc (rotor).
    NOTE
    If the rotor cannot be easily removed, turn the shoe adjuster until the wheel turns freely.



    Click image to see an enlarged view

    Fig. If you have difficulty removing the rotor, turn the shoe adjuster until the wheel turns freely

  10.  
  11. Inspect the brake disc (rotor) inside diameter, as follows:
    1. Using a brake drum gauge or equivalent, measure the inside diameter of the disc and compare with the following: Standard inside diameter: 190 mm (7.48 in.). Maximum inside diameter: 191 mm (7.52 in.)
    2.  
    3. If the inside diameter exceeds the maximum, replace the brake disc.

      Click image to see an enlarged view

      Fig. Use a brake drum gauge to measure the inside of the disc

    4.  

  12.  
  13. Use needle-nose pliers to remove the 2 parking brake shoe return tension springs.

    Click image to see an enlarged view

    Fig. Use a needle-nose pliers to remove the 2 return tension springs

  14.  
  15. Remove the parking brake shoe strut, as follows:
    1. Remove the parking brake shoe strut and the parking brake shoe strut compression spring.
    2.  

  16.  
  17. Remove parking brake shoe no.1, as follows:
    1. Remove the parking brake shoe hold down spring cup No.1, parking brake shoe hold down spring and parking brake shoe hold down spring cup no.2.

      Click image to see an enlarged view

      Fig. Remove the parking brake shoe hold-down spring cups

    2.  
    3. FWD vehicles, remove the parking brake shoe hold down spring pin No.1.
    4.  
    5. Disconnect the parking brake shoe return spring no.2 and remove the parking brake shoe assembly lh no.1.
    6.  

  18.  
  19. Remove parking brake shoe adjusting screw set:
    1. Remove the parking brake shoe adjusting screw set.
    2.  
    3. Remove the parking brake shoe return tension spring No.2.

      Click image to see an enlarged view

      Fig. Remove the parking brake shoe adjusting screw set and shoe return spring

    4.  

  20.  
  21. Remove parking brake shoe assembly no.2:
    1. Remove the parking brake shoe hold down spring cup No.1, parking brake shoe hold down spring, parking brake shoe hold down spring cup no.2 and parking brake shoe hold down spring pin no.2.
    2.  
    3. Remove the parking brake shoe assembly lh no.2.
    4.  
    5. Using needle-nose pliers, disconnect the parking brake cable no.3 from the parking brake cable shoe lever.
      WARNING
      Be careful not to damage parking brake cable no.3.



      Click image to see an enlarged view

      Fig. Using needle-nose pliers, disconnect the parking brake cable no.3 from the parking brake cable shoe lever

    6.  

  22.  
  23. On 4WD models, separate the rear speed sensor.
  24.  
  25. On 4WD models, remove the rear axle shaft nut.
  26.  
  27. On 4WD models, remove rear axle hub & bearing assembly
  28.  
  29. On 4WD models, remove parking brake shoe hold down spring pin.
  30.  
  31. Remove parking brake shoe type C-washer, as follows:
    1. Using a screwdriver, remove the c-washer.
    2.  
    3. Remove the shim and parking brake shoe lever from the parking brake shoe no.2.
    4.  

  32.  
  33. Inspect parking brake shoe lining thickness:
    1. Using a ruler, measure the thickness of the shoe lining. Standard thickness is 2.5 mm (0.098 in.) and minimum thickness is 1.0 mm (0.039 in.). If the lining thickness is less than or equal to the minimum, or If there is severe or uneven wear, replace the brake shoe.
    2.  

  34.  
  35. Inspect brake disc and parking brake shoe lining for proper contact
    1. Apply chalk to the inside surface of the disc, then grind down the brake shoe lining to fit disc.
    2.  
    3. If the contact between the brake disc and the shoe lining is improper, repair it using a brake shoe grinder or replace the brake shoe assembly.

      Click image to see an enlarged view

      Fig. Exploded view of the parking brake components-2004-06 FWD vehicles



      Click image to see an enlarged view

      Fig. Exploded view of the parking brake components-2004-06 4WD vehicles

    4.  

  36.  

To install:

 
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