Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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WARNING: Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health. Avoid breathing dust particles. NEVER use an air hose or brush to clean brush assembly. Use an OSHA-approved vacuum cleaner. REAR DISC BRAKE PADS Removal Raise and support vehicle. Remove wheels. Thoroughly clean outside of caliper to prevent dust and dirt from entering inside. Support caliper with a piece of wire to prevent damage to brake hose. Remove 2 caliper bolts and caliper from bracket. Remove pad shims and pads. Using vernier calipers, measure the thickness of each brake pad lining. Measurement does not include pad backing plate thickness. See DISC BRAKE SPECIFICATIONS . Remove pad retainers. Inspection Clean caliper thoroughly; remove any rust, and check for grooves and cracks. Check brake disc for damage and cracks. Measure brake pad thickness. See DISC BRAKE SPECIFICATIONS . If brake pad thickness is less than service limit, replace pads as a set. Installation 1. Install pad retainers. Apply Molykote M77 compound onto pad side of shim. Wipe excess grease off shim. Keep grease off discs and pads. Install brake pads and shims. Install inner pad with its wear indicator facing downward. If you are reusing pads, install in original position. Rotate caliper piston clockwise into cylinder, then align cutout in piston with tab on inner pad by turning piston back. See Fig. 15 . 2. Lubricate boot with rubber grease to avoid twisting. If boot is twisted, back it out and position properly. Install brake caliper. Install and torque caliper bolts to proper specification. See TORQUE SPECIFICATIONS . Install brake hose onto suspension arm with mounting bolt. After installation, check for leaks. Pump brake pedal several times to seat pads. Bleed brakes as necessary. See BLEEDING BRAKE SYSTEM . NOTE: Engagement of brake may require a greater pedal stroke immediately after brake pads have been replaced as a set. Several applications of brake pedal will restore normal pedal stroke.

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Introduction Some 2010 Prius vehicles may experience rear brake squeak when backing up or moving forward during the ?rst few brake applications when the brakes are cold. An updated rear brake shim kit is available to reduce the likelihood of this condition occurring. Repair Procedure 1. Test drive the vehicle to con?rm the squeak is coming from the rear brakes. The condition occurs more frequently when backing up during light brake pedal application after cold soak. 2. Remove rear brake shims. Refer to the Technical Information System (TIS) 2010 Prius Repair Manual: Brake – Brake (Rear) Brake: Rear Brake: Removal 3. Clean the rear brake pad backing plates with a clean shop towel and apply a small amount of black disc brake grease to the backing plate of each rear brake pad. NOTE Make sure disc brake grease is not applied to the lining of the rear brake pads. 4. Install the No. 1 Anti-squeal shims. Install the No. 2 Anti-squeal shims. Figure 3. 5. Using the Variable Pin Wrench (SST 09960-10010), slowly rotate the caliper piston until the piston groove is positioned as shown in the illustration below. 6. Install new rear brake anti-squeal shims with brake pads into the rear caliper assemblies brackets. Refer to (TIS), 2010 Prius Repair Manual: Brake – Brake (Rear) Brake: Rear Brake: Installation NOTE • When installing the rear disc brake caliper assembly on the rear disc brake caliper mounting bracket, ensure the protrusion on the brake pad is centered in the caliper piston groove. • It is important to ensure the protrusion is not contacting the outer edges of the caliper piston groove. (both sides) 7. Road test the vehicle to con?rm the condition has been reduced.

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WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in personal injury. CAUTION: Do not spill brake fluid onto painted or plastic surfaces. If spilled, wipe up immediately before damage to the plastic or painted surfaces occurs. 1. Remove the wheel and tire assembly. For additional information, refer to Section 204-00. 2. Remove the parts in the order indicated in the following illustration and table. To remove individual parts, only carry out the listed steps: 3. To install, reverse the removal procedure. 4. If the hydraulic system was opened, bleed the brake system. For additional information, refer to Brake System Bleeding in this section. Item 2: Brake Caliper Removal Note 1. CAUTION: Do not allow the brake caliper to hang by the flexible brake hose. Support the caliper to the vehicle. Item 11: Brake Disc Removal Note 1. If removing the brake disc, only remove the caliper bracket bolts and position the caliper and bracket aside. Item 10: Spindle Nut Installation Note 1. Tighten the spindle nut to the specified torque. Rotate the hub counter-clockwise 5 rotations and then recheck the torque. Item 3: Brake Disc Pads Installation Note 1. CAUTION: Install a new lining if worn to or past the specified thickness above the metal backing plate or if the pad is damaged. Install new pads in complete axle sets. If replacing the brake pads, use a suitable suction device, remove the brake fluid in the master cylinder reservoir until it is half filled. 2. If replacing the brake pads, use a suitable tool to push the brake caliper pistons into the caliper bore. 3. One brake disc pad kit contains the pads required for both the RH and LH side. Item 1: Caliper Bolt Installation Note 1. Tighten the bottom caliper bolt and then the top caliper bolt. Item 11: Brake Disc Inspection Note 1. NOTE: If machining is necessary use a hub-mount brake lathe to machine the front brake disc. For additional information, refer to section Section 100-04. Measure the front brake disc, and resurface as necessary. Install a new front brake disc if beyond specification.

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Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health. Avoid breathing dust particles. Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner. Inspection 1. Raise the rear of the vehicle, and support it with safety stands in the proper locations. 2. Remove the rear wheels. 3. Check the thickness (A) of the inner pad (B) and the outer pad (C). Do not include the thickness of the backing plate. 4. If any of the brake pad thickness is less than the service limit, replace the rear brake pads as a set. 5. Clean the mating surfaces between the brake disc and the inside of the wheel, then install the rear wheels. Replacement 1. Remove some brake fluid from the master cylinder. 2. Raise the rear of the vehicle, and support it with safety stands in the proper locations. 3. Remove the rear wheels. 4. Remove the brake hose mounting bolt (A). 5. Remove the flange bolts (B) while holding respective caliper pin (C) with a wrench. Be careful not to damage the pin boot, and remove the caliper (D). Check the hose, the pin boots, and the parking brake cable boots for damage and deterioration. NOTE: Do not twist the brake hose and the parking brake cable to prevent damage. 6. Remove the pad shim (A) and the brake pads (B). 7. Remove the pad retainers (A). 8. Clean the caliper bracket (B) thoroughly; remove any rust, and check for grooves and cracks. Verify that the caliper pins (C) move in and out smoothly. Clean and lube if needed. 9. Inspect the brake disc, and check for damage and cracks. 10. Apply a thin coat of M-77 assembly paste (P/N 08798-9010) to the retainer mating surface of the caliper bracket (indicated by the arrows and shaded area). 11. Install the pad retainers. Wipe excess assembly paste off the retainers. Keep the assembly paste off the brake disc and the brake pads.

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REAR DISC BRAKE PADS Removal Raise and support rear of vehicle. Remove wheels and release parking brake. Remove caliper shield (if equipped). Remove caliper mounting bolts. Remove caliper from bracket. Suspend caliper using wire. Remove brake pads. Inspection Using a vernier caliper, measure friction pad thickness. Service limit is .06″ (1.5 mm). Installation 1. Apply Molykote M77 compound to pad side of inner and outer pad shims. Install brake pads and shims. Rotate caliper piston clockwise in caliper (if necessary). Ensure cutout in piston aligns with tab on inner pad. 2. Avoid twisting piston boot. If boot is twisted, back out piston and reposition boot. Install brake caliper and parking brake cable. Install caliper shield. Tighten shield mounting bolts to specification. See TORQUE SPECIFICATIONS. 3. Pump brake pedal several times to seat pads. Bleed brakes as necessary. See BLEEDING BRAKE SYSTEM.