TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine BR08W−01
BR−14
− BRAKEBRAKE MASTER CYLINDER
1996 TOYOTA T100 (RM449U)
INSPECTION
HINT:
Clean the disassembled parts with compressed air.
1. INSPECT CYLINDER BORE FOR RUST OR SCORING
2. INSPECT CYLINDER FOR WEAR OR DAMAGE
If necessary, clean or replace the cylinder.

Downloaded from www.Manualslib.com manuals search engine BR08X−01
− BRAKEBRAKE MASTER CYLINDER
BR−15
1996 TOYOTA T100 (RM449U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page BR−12).
NOTICE:
Apply lithium soap base glycol grease to the rubber parts indicated by the arrows
(See page BR−9).

Downloaded from www.Manualslib.com manuals search engine BR08Y−01
BR−16
− BRAKEBRAKE MASTER CYLINDER
1996 TOYOTA T100 (RM449U)
INSTALLATION
Installation is in the reverse order of removal (See page BR−11).
1. BEFORE INSTALLATION, ADJUST LENGTH OF BRAKE BOOSTER PUSH ROD
(See page BR−20)
2. AFTER INSTALLATION, FILL BRAKE RESERVOIR WITH BRAKE FLUID. AND BLEED BRAKE
SYSTEM (See page BR−4)
3. CHECK FOR LEAKS, CHECK AND ADJUST BRAKE PEDAL (See page BR−6)

Downloaded from www.Manualslib.com manuals search engine BR2237
BR08Z−01
BR2238
GOOD NO GOOD
1st2nd3rd
− BRAKEBRAKE BOOSTER ASSEMBLY
BR−17
1622 Author: Date:
1996 TOYOTA T100 (RM449U)
BRAKE BOOSTER ASSEMBLY
ON−VEHICLE INSPECTION
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 CHECK
(a) Start the engine and stop it after 1 or 2 minutes. Depress
the brake pedal several times slowly.
If the pedal goes down furthest the 1st time, but gradually rises
after the 2nd or 3rd time, the booster is air tight.
(b) Depress the brake pedal while the engine is running, and
stop it with the pedal depressed. If there is no change in
pedal reserve travel after holding the pedal for 30 se-
conds, the booster is air tight.

Downloaded from www.Manualslib.com manuals search engine BR090−02
R14753
R14753
Master Cylinder
Non−reusable part 3−Way UnionBrake Booster Gasket
Clevis
Clip Clevis Pin
ClampGasket
N·m (kgf·cm, ft·lbf) : Specified torque
15 (155, 11)
13 (130, 9)
25 (260, 19)13 (130, 9)
BR−18
− BRAKEBRAKE BOOSTER ASSEMBLY
1996 TOYOTA T100 (RM449U)
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine BR091−01
BR3285
− BRAKEBRAKE BOOSTER ASSEMBLY
BR−19
1996 TOYOTA T100 (RM449U)
REMOVAL
1. REMOVE MASTER CYLINDER (See page BR−11)
2. DISCONNECT VACUUM HOSE FROM BRAKE
BOOSTER
3. REMOVE PEDAL RETURN SPRING
4. REMOVE CLIP AND CLEVIS PIN
5. REMOVE BRAKE BOOSTER
(a) Remove the 4 nuts and clevis.
(b) Pull out the brake booster and gasket.

Downloaded from www.Manualslib.com manuals search engine BR092−01
BR3286
F03521
SST
Gasket
Z03607
SST BR−20
− BRAKEBRAKE BOOSTER ASSEMBLY
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. INSTALL BRAKE BOOSTER
(a) Install the booster and a new gasket.
(b) Install the clevis to the operating rod.
(c) Install and torque the booster installation nuts.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
(d) Install the clevis pin into the clevis and brake pedal, and
install the clip to the clevis pin.
(e) Install the pedal return spring.
2. ADJUST LENGTH OF BOOSTER PUSH ROD
(a) Install a new gasket on the master cylinder.
(b) Set the SST on the gasket, and lower the pin until its tip
slightly touches the piston.
SST 09737−00010
(c) Turn the SST upside down, and set it on the booster.
SST 09737−00010
(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 light-
ly touches the pin head.
3. INSTALL MASTER CYLINDER (See page BR−16)
4. CONNECT VACUUM HOSE TO BRAKE BOOSTER
5. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND
BLEED BRAKE SYSTEM (See page BR−4)
6. CHECK FOR FLUID LEAKAGE
7. CHECK AND ADJUST BRAKE PEDAL
(See page BR−6)
Check and adjust the brake pedal, then tighten the clevis lock
nut.
Torque: 25 N·m (260 kgf·cm, 19 ft·lbf)
8. DO OPERATIONAL CHECK (See page BR−17)

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Z18924
PadAnti−Squeal Spring
Pad Wear Indicator Plate 1 ton :
Anti−Squeal Shim Pad Support PlateInner Anti Squeal Shim
Disc brake grease
Pad Pad Support Plate
Pad Wear
Indicator Plate 0.5 ton :Bleeder Plug
Dust Boot
Sliding Bushing
Brake Caliper
Dust Boot
Set Ring Torque PlatePiston
Piston Seal
BootGasket

Anti−Squeal Shim

Gasket

Brake Caliper
Piston Seal
Piston
Boot
Dust Boot  Bleeder Plug
Torque PlateSliding Pin
Lithium soap base glycol grease
Non−reusable part 
39 (400, 29)
36 (370, 27)
N·m (kgf·cm, ft·lbf)
: Specified torque
− BRAKEFRONT BRAKE PAD (2WD)
BR−21
1626 Author: Date:
1996 TOYOTA T100 (RM449U)
FRONT BRAKE PAD (2WD)
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine BR094−01
BR3082
R04837
BR3312
BR−22
− BRAKEFRONT BRAKE PAD (2WD)
1996 TOYOTA T100 (RM449U)
REPLACEMENT
1. REMOVE FRONT WHEEL
Remove the wheel and temporarily fasten the disc with hub
nuts.
2. INSPECT PAD LINING THICKNESS
Check the pad thickness through the caliper inspection hole
and replace pads if not within specification.
Minimum thickness: 1.0 mm (0.039 in.)
3. LIFT UP CALIPER
(a) Remove the installation bolt.
(b) Lift up the caliper and suspend it securely.
HINT:
Do not disconnect the flexible hose from the caliper.
4. REMOVE THESE PARTS:
1 ton:
2 anti−squeal springs
2 brake pads
2 (1 ton) / 4 (0.5 ton) anti−squeal shims
2 pad wear indicator plates
4 pad support plates
NOTICE:
The anti−squeal springs (1 ton) and 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−30)
6. INSTALL 4 PAD SUPPORT PLATES
7. INSTALL NEW PADS
NOTICE:
When replacing worn pads, the anti−squeal shims and
wear indicator plates must be replaced together with the
pads.
(a) Install a pad wear indicator plate to the pad.
(b) 1 ton:
Install the anti−squeal shim to each pad.
(c) 0.5 ton:
Install the 4 anti−squeal shims to each pad.
HINT:
Apply disc brake grease to both sides of inner anti−squeal
shims (See page BR−21).

Downloaded from www.Manualslib.com manuals search engine R05057
R05256
− BRAKEFRONT BRAKE PAD (2WD)
BR−23
1996 TOYOTA T100 (RM449U)
(d) Install the 2 pads so that the wear indicator plate is facing
underneath.
NOTICE:
Do not allow oil or grease 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 equivalent.
HINT:
If the piston is difficult to push in, loosen the bleeder plug and
push in the piston while letting some brake fluid escape.
(c) Insert the brake caliper carefully so the boot is not
wedged.
(d) Install and torque the installation bolts.
Torque:
1 ton: 39 N·m (400 kgf·cm, 29 ft·lbf)
Torque:
0.5 ton: 36 N·m (370 kgf·cm, 27 ft·lbf)
9. INSTALL FRONT WHEEL
10. CHECK THAT FLUID LEVEL IS AT MAX LINE