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

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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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Getting started 1. Apply the handbrake. 2. Place chocks under the front wheels and engage 1st gear. Remove the Brake Caliper 6. The brake caliper needs to be removed to allow the brake disc to be removed. Working under the car remove the clip securing the brake hose in place. 3. Loosen the rear wheel nuts using a 19mm wheel wrench with the car on the ground. 4. Jack up the car and support safely using axle stands or ramps. Preferably jack up both sides at the same time, as it makes it easier to balance the handbrake action at the end. This will free the hose and pipe. Carefully slip the pipe fitting out of the bracket. 7. Remove the caliper lower fixing bolt (16mm socket). 5. Remove the road wheel. 8. Remove the plastic cap over the upper fixing bolt. Remove the Brake Disc 11. Loosen the brake disc holding screw using a T-30 Torx bit. 9. Use a 6mm allan key to remove the upper fixing bolt. 12. Release the hand brake and remove the brake disc. If this proves difficult, it may be necessary loosen the brake adjuster. To do this, remove the rubber plug…. 10. The caliper will now be loose and can be carefully lifted away from the disc, taking care to route the brake pipe gently to avoid strain. Support the caliper from the suspension spring using string or ties. …and turn the adjuster with a screwdriver inserted through the hole. The disc has been removed here to show the teeth on the adjuster.

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WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer’s specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. 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 serious personal injury. WARNING: Always install new brake shoes or pads at both ends of an axle to reduce the possibility of brakes pulling vehicle to one side. Failure to follow this instruction may result in uneven braking and serious personal injury. NOTICE: Do not spill brake fluid onto painted or plastic surfaces or damage to surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. 1. Check the brake fluid level in the brake master cylinder reservoir. If required, remove the fluid until the brake master cylinder reservoir is half full. 2. Remove the wheel and tire. For additional information, refer to Section 204-04. 3. NOTICE: Do not allow the brake caliper to hang by the flexible brake hose or damage to the hose may occur. Remove the 2 brake caliper guide pin caps and bolts and position the caliper and brake pad assembly aside. Support the caliper using mechanic’s wire. Remove and discard the guide pin bushings. Inspect the guide pin threads for damage, install new guide pin(s) as necessary. 4. Remove the brake pads from the caliper. 5. Inspect the brake pads for wear or contamination and install new pads as necessary. For additional information, refer to General Procedures in Section 206-00. 6. Using a C-clamp and a worn brake pad, press the piston into the caliper. 7. Inspect the brake disc and resurface or install a new brake disc as necessary. For additional information, refer to General Procedures in Section 206-00. Installation 1. Clean, dry and inspect the brake caliper anchor plate. Apply equal amounts of the supplied yellow lubricant to the 4 brake pad contact points on the anchor plate as shown. 2. NOTICE: Do not apply lubricant to guide pin threads or incorrect tightening of the guide pins may result. Install new brake hardware as follows: Apply equal amounts of the supplied white lubricant to the inside of the guide pin bushings. Install the guide pin bushings into the caliper bores. Install the guide pins into the bushings. 3. Install the brake pads to the caliper. 4. Position the caliper onto the anchor plate and install the 2 brake caliper guide pin bolts. To install, tighten to 38 Nm (28 lb-ft). Clean and dry guide pin threads as necessary. 5. Fill the master cylinder with clean, specified brake fluid. 6. Install the wheel and tire. For additional information, refer to Section 204-04. 7. Apply the brake several times to verify correct brake operation.

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Removal All vehicles 1. Remove the wheel and tire. For additional information, refer to Section 204-04. Vehicles with rear drum brakes 2. Disconnect the brake tube. 1. Clamp the flexible brake hose. 2. Disconnect the brake tube union. 3. Remove the retaining clip. 4. Detach the flexible brake hose. Vehicles with rear disc brakes 3. Detach the flexible brake hose and the brake pad wear sensor wiring loom (if equipped) from the strut and spring assembly. 4. Disconnect the brake pad wear sensor electrical connector (if equipped). 5. Detach the anti-lock brake system (ABS) sensor and wiring loom. All Vehicles 6. Detach the stabilizer bar connecting link and bushing from the front arm. 7. Detach the rear arm from the wheel spindle. 8. Detach the tie-bar from the wheel spindle. 9. Detach the front arm from the wheel spindle. 10. Remove the wheel spindle to strut and spring assembly pinch bolt. 11. CAUTION: Secure the wheel spindle to prevent damage to the parking brake cable and brake hose (disc brake vehicles only). Detach the wheel spindle from the strut and spring assembly. 12. Detach the strut and spring assembly from the crossmember. 1. Raise the strut and spring assembly on a jack. 2. Detach the strut and spring assembly from the crossmember. 13. Remove the strut and spring assembly.

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Removal 1. CAUTION: Install a new lining if worn to or past the specified thickness above the metal backing plate or rivets. Install new pads in complete axle sets. If necessary, using a suitable suction device, remove the brake fluid in the master cylinder reservoir until it is half filled. 2. Remove the wheel and tire assembly. For additional information, refer to Section 204-04. 3. Inspect the brake pads for wear or contamination. 4. CAUTION: If the anchor housing spring is to be reused, do not force the anchor housing spring off the brake caliper. Do not install a damaged anchor housing spring. Remove the anchor housing spring. 5. NOTE: Verify if the anchor housing spring has 1 end with 2 tabs. If yes, the LH side anchor housing spring must be installed with the 2-tabbed end in the upper brake caliper cavity. For the LH brake caliper, release the lower portion of the anchor housing spring. Apply force at the center of the anchor housing spring and pull outward at the bottom of the anchor housing spring to remove it from the lower brake caliper cavity. 6. Rotate the spring upward then remove it from the brake caliper. 7. NOTE: On the RH side, the anchor housing spring must be installed with the 2-tabbed end in the lower brake caliper cavity. The illustration below shows the anchor housing spring end with 2 tabs. For RH brake caliper, release the upper portion of the anchor housing spring. Apply force at the center of the anchor housing spring and pull outward at the top of the anchor housing spring to remove it from the upper brake caliper cavity. 8. Rotate the spring downward then remove it from the brake caliper. 9. NOTE: Do not allow the brake caliper to hang from the brake hose. Remove the brake caliper. 1. Remove the zero-drag spring. 2. Remove and discard the brake caliper-to-anchor plate bolts, guide pins and boots. 10. Remove the brake pads from the brake caliper. 11. NOTE: Use a wood block or used brake pad to protect the brake caliper piston boots. Compress the brake caliper pistons. 12. Measure the brake disc thickness. Install a new brake disc if it is not within specification. For additional information, refer to Brake Disc in this section.