TOYOTA LAND CRUISER 1996 J80 Workshop Manual

BR1CW−01
BR−28
−
BRAKE FRONT BRAKE CALIPER
1996 LAND CRUISER (RM451U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page BR−26 ).
NOTICE:
Apply lithium soap base glycol grease to the parts indicated by the arro\
ws (See page BR−33).
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BR1CY−01
−
BRAKE FRONT BRAKE CALIPER
BR−29
1996 LAND CRUISER (RM451U)
INSTALLATION
Installation is in the reverse order of removal (See page BR−25 ).
HINT:
After installation, fill the brake reservoir with brake fluid, bleed bra\
ke system (see page BR−4) and check
for leaks.
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BR1CZ−02
BR−30
−
BRAKE REAR BRAKE PAD
1012
Author: Date:
1996 LAND CRUISER (RM451U)
REAR BRAKE PAD
COMPONENTS
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BR1D0−03
−
BRAKE REAR BRAKE PAD
BR−31
1996 LAND CRUISER (RM451U)
REPLACEMENT
1. REMOVE REAR WHEEL
Remove the wheel and temporarily fasten the disc with the hub
nuts.
2. INSPECT PAD LINING THICKNESS
Check the pad thickness through the caliper inspection hole
and replace pads if the thickness is not within the specification.
Minimum thickness: 1.0 mm (0.039 in.)
3. REMOVE BRAKE CALIPER
(a) Remove the sliding main pin and sliding sub pin.
(b) Remove the caliper and suspend it so the hose is not stretched.
HINT:
Do not disconnect the flexible hose.
4. REMOVE THESE PARTS:
(a) 2 brake pads
(b) Anti−squeal shim
(c) 4 pad support plates
(d) 2 pad wear indicator plates
NOTICE:
The pad support plates can be used again provided that
they have sufficient rebound, no deformation, cracks or
wear, and have had all rust, dirt and foreign particles
cleaned off.
5. CHECK DISC THICKNESS AND RUNOUT (See page BR−36 )
6. INSTALL PAD SUPPORT PLATES
7. INSTALL NEW PADS
NOTICE:
When replacing worn pads, the anti −squeal shim and wear
indicator plates must be replaced together with the pads.
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BR−32
−
BRAKE REAR BRAKE PAD
1996 LAND CRUISER (RM451U)
(a) Install pad wear indicator plate to each pads.
(b) Install the anti−squeal shim to the outer pad.
(c) Install the 2 pads so the wear indicator plate is facing up-
ward.
NOTICE:
Do not allow oil or grease to get on the rubbing face.
8. INSTALL CALIPER
(a) Draw out a small amount of brake fluid from the reservoir.
(b) Press in piston with a hammer handle or an equivalent.
HINT:
Always change the pads on one wheel at a time as there is a
possibility of the opposite piston flying out.
(c) Install the caliper carefully so the boot is not wedged.
(d) Install and torque the sliding main pin and sub pin. Torque: 88 N·m (900 kgf·cm, 65 ft·lbf)
9. INSTALL REAR WHEEL
10. CHECK THAT FLUID LEVEL IS AT MAX LINE
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BR1D1−01
−
BRAKE REAR BRAKE CALIPER
BR−33
1015
Author: Date:
1996 LAND CRUISER (RM451U)
REAR BRAKE CALIPER
COMPONENTS
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BR1D2−01
BR−34
−
BRAKE REAR BRAKE CALIPER
1996 LAND CRUISER (RM451U)
REMOVAL
1. DISCONNECT FLEXIBLE HOSE
(a) Remove the union bolt and 2 gaskets from the caliper, then disconnect the flexible hose from the cali-
per.
Torque: 30 N·m (310 kgf·cm, 22 ft·lbf)
(b) Use a container to catch the brake fluid as it drains out.
2. REMOVE CALIPER
Remove the 2 sliding pins and caliper. Torque: 88 N·m (900 kgf·cm, 65 ft·lbf)
3. REMOVE THESE PARTS:
(a) 2 pads with anti −squeal shim
(b) 4 pad support plates
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BR1D3−01
−
BRAKE REAR BRAKE CALIPER
BR−35
1996 LAND CRUISER (RM451U)
DISASSEMBLY
1. REMOVE CYLINDER BOOT
Using a screwdriver, remove the cylinder boot from the caliper.
2. REMOVE PISTON
(a) Place a piece of cloth or similar article between the piston
and the caliper.
(b) Use compressed air to remove the piston from the cylin- der.
CAUTION:
Do not place your fingers in front of the piston when using
compressed air.
3. REMOVE PISTON SEAL
Using a screwdriver, remove the piston seal from the cylinder.
4. REMOVE DUST BOOT AND SLIDING BUSHING
Using a screwdriver and hammer, tap out dust boot and sliding
bushing.
HINT:
Tape the screwdriver tip before use.
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BR1D5−03
BR−36
−
BRAKE REAR BRAKE CALIPER
1996 LAND CRUISER (RM451U)
INSPECTION
1. MEASURE PAD LINING THICKNESS (See step 1. on page BR−27)
Standard thickness: 10.0 mm (0.394 in.)
Minimum thickness: 1.0 mm (0.039 in.)
2. MEASURE DISC THICKNESS (See page BR−27 )
Standard thickness: 18.0 mm (0.709 in.)
Minimum thickness: 16.0 mm (0.630 in.)
3. MEASURE DISC RUNOUT (See page BR−27 )
Maximum disc runout: 0.15 mm (0.0059 in.)
If the runout is greater than the maximum, adjust the disc runout
or grind it on a ”On−Car” brake lathe.
4. IF NECESSARY, REPLACE DISC
(a) Remove the torque plate..
(b) Remove the hub nuts of the temporarily installed disc and
pull off the disc.
(c) Install a new disc and and loosely install the hub nuts.
(d) Install the torque plate and tighten the mounting bolts. Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)
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BR1D4−01
−
BRAKE REAR BRAKE CALIPER
BR−37
1996 LAND CRUISER (RM451U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page BR−35 ).
NOTICE:
Apply lithium soap base glycol grease to the parts indicated by the arro\
ws (See page BR−33).
Brought to you by BirfMark
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Version 1.11 - 03/16/2010