brake system TOYOTA LAND CRUISER 1996 J80 User Guide

BR1CD−01
BR−2
−
BRAKE TROUBLESHOOTING
984
Author: Date:
1996 LAND CRUISER (RM451U)
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers \
indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
Low pedal or spongy pedal
4. Fluid leaks for brake system
5. Air in brake system
6. Piston seals: worn or damaged
7. Master cylinder: faulty
8. Booster push rod: out of adjustment−
−
BR−33
BR−33 BR−9
BR−20
Brake drag
1. Brake pedal freeplay: minimal
2. Parking brake lever travel: out of adjustment
3. Parking brake wire: sticking
4. Pad: cracked or distorted
5. Piston: stuck
6. Piston: frozen
7. Tension or return spring: faulty
8. Booster push rod: out of adjustment
9. . Vacuum leaks for booster system
10.. Master cylinder: faultyBR−6
BR−8 −
BR−21
BR−30
BR−33
BR−33
BR−33
BR−33
BR−39
BR−20
BR−18 BR−9
Brake pull
1. Piston: stuck
2. Pad: oily
3. Piston: frozen
4. Disc: Scored
5. Pad: cracked or distortedBR−33
BR−33
BR−21
BR−30
BR−33
BR−33
BR−33
BR−33
BR−21
BR−30
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−
BRAKE TROUBLESHOOTING
BR−3
985
Author: Date:
1996 LAND CRUISER (RM451U)
Hard pedal but brake inef
ficient
1. Fluid leaks for brake system
2. Air in brake system
3. Pad: worn
4. Pad: cracked or distorted
5. Pad: oily
6. Pad: glazed
7. Disc: scored
8. Booster push rod: out of adjustment
9. Vacuum leaks for booster system−
−
BR−21
BR−30
BR−21
BR−30
BR−21
BR−30
BR−21
BR−30
BR−21
BR−30
BR−20
BR−18
Noise from brake
1. Pad: cracked or distorted
2. Installation bolt: loosen
3. Disc: scored
4. Pad support plate: loosen
5. Sliding pin: worn
6. Pad: dirty
7. Pad: glazed
8. Tension or return spring: faulty
9. Anti− squeal shim: damaged
10.. Hold− down spring: damagedBR−21
BR−30
BR−33
BR−33
BR−33
BR−33
BR−30
BR−33
BR−21
BR−30
BR−21
BR−30
BR−39
BR−21
BR−30
BR−39
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BR1CE−01
R13494
R00252
BR−4
−
BRAKE BRAKE FLUID
986
Author: Date:
1996 LAND CRUISER (RM451U)
BRAKE FLUID
BLEEDING
HINT:
If any work is done on the brake system or if air is suspected in
the brake lines, bleed the system of air.
NOTICE:
Do not let brake fluid remain on a painted surface. Wash it
off immediately.
1. FILL BRAKE RESERVOIR WITH BRAKE FLUID
Check the fluid level in the reservoir after bleeding each wheel.
Add fluid, if necessary. Fluid: SAE J1703 or FMVSS No.116 DOT3
2. BLEED MASTER CYLINDER
HINT:
If the master cylinder has been disassembled or if the reservoir
becomes empty, bleed the air from the master cylinder.
(a) Disconnect the brake lines from the master cylinder.
(b) Slowly depress the brake pedal and hold it.
(c) Block off the outlet plugs with your fingers, and release the brake pedal.
(d) Repeat (b) and (c) 3 or 4 times.
3. CONNECT VINYL TUBE TO BRA KE CALIPER BLEED-
ER PLUG
Insert other end of the tube in a half −full container of brake fluid.
NOTICE:
Begin bleeding air from the brake caliper with the longest
hydraulic line.
4. BLEED BRAKE LINE
(a) Slowly depress the brake pedal several times.
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BR3297
Pedal Reserve Distancea
−
BRAKE BRAKE PEDAL
BR−7
989
Author: Date:
1996 LAND CRUISER (RM451U)
If incorrect, check the stop light switch clearance.
If the clearance is OK, then troubleshoot the brake system.
4. CHECK PEDAL RESERVE DISTANCE
Release the parking brake.
With the engine running, depress the pedal and measure
the pedal reserve distance, as shown.
Pedal reserve distance, ’a’, at 490 N (50 kgf, 110.2lbf):
More than 68 mm (2.68 in.)
If the reserve distance incorrect, troubleshoot the brake sys-
tem.
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BR1CQ−01
BR3976
SST
Gasket
R11347
SST
BR−20
−
BRAKE BRAKE BOOSTER ASSEMBLY
1996 LAND CRUISER (RM451U)
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−9 )
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 )
8. DO OPERATIONAL CHECK (See page BR−17 )
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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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BR1D6−01
BR−38
−
BRAKE REAR BRAKE CALIPER
1996 LAND CRUISER (RM451U)
INSTALLATION
Installation is in the reverse order of removal (See page BR−34 ).
HINT:
After installation, fill brake reservoir with brake fluid, bleed brake system\
(See page BR−4) and check for
leaks.
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BR1DH−01
R05477
A
BR−52−
BRAKE LOAD SENSING PROPORTIONING AND BY− PASS
VALVE (LSP & BV)
1996 LAND CRUISER (RM451U)
INSTALLATION
1. INSTALL LSP & BV ASSEMBLY
Install the LSP & BV assembly to the frame with the 4 bolts. Torque: 25 N·m (260 kgf·cm, 19 ft·lbf)
2. CONNECT SHACKLE NO.2 TO BRACKET
(a) Set the dimension A by turning shackle No.2. Initial set: 90 mm (3.54 in.)
(b) Tighten the lock nut. Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(c) Install the 2 bushings and collar to the load sensing spring
shackle.
(d) Install the load sensing spring shackle to the shackle bracket with a retainer and nut.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
(e) Install a new cotter pin.
3. CONNECT BRAKE LINES
Using SST, connect the 3 brake lines. SST 09751−36011
Torque: 15 N·m (155 kgf·cm, 11 ft·lbf)
4. SET REAR AXLE LOAD (See page BR−45 )
5. SET VALVE BODY
(a) When pulling down the load sensing spring, confirm that the valve piston moves down smoothly.
(b) Position the valve body so that the valve piston lightly contacts the load sensing spring.
(c) Tighten the 2 valve body mounting nuts. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
6. BLEED BRAKE SYSTEM (See page BR−4 )
7. CHECK FLUID LEAKAGE
8. CHECK AND ADJUST LSP & BV FLUID PRESSURE (See page BR−45 )
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BR1DL−01
−
BRAKE ABS ACTUATOR
BR−59
1996 LAND CRUISER (RM451U)
INSTALLATION
Installation is in the reverse order of removal (See page BR−57 ).
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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DI5K4−03
Vehicle Brought to Workshop
Customer Problem Analysis
Check DTC and Freezes Frame Data (Pre−check)
Record or Print DTC and Freezed Frame Data
DI−131
Clear DTC and Freezed Frame Data DI−131
Visual Inspection
Setting the Check Mode Diagnosis
DI−131
1
Items insideare titles of pages in this manual, with the
page number indicated in the bottom portion. See the indicated
pages for detailed explanations.
Connect an OBD II scan tool or TOYOTA hand−held tester to DLC3.
If your display shows ”UNABLE TO CONNECT TO VEHICLE” when you have connected the
scan tool/TOYOTA hand− held tester, inspect DLC3
DI−131
2
3
4
5
6
symptom does not occur
Problem Symptom Confirmation8
7Symptom Simulation
symptom occurs
DTC Check
DI−131 OK Code
11Preliminary Check
DTC ChartMechanical System Tests
Manual Shifting Test
OK
OK
Chapter 1
(Electronic) Chapter 2
(On−Vehicle)OKChapter 3
(Off
−Vehicle)OK
Matrix Chart of Problem Symptoms
− DI−147
Circuit
InspectionStop Light Signal
 O/D Cancel Signal Check
NG
Parts Inspection
NG
NG NG
Identification of ProblemRepairConfirmation TestEnd
NG
NG
12
NG13
14
15 16
17
9
10
DI−153 − DI−185
18
DI−130
DI−143
DI−131
DI−131
DI−131
DI−147 DI−147
DI−147
P.IN−18
Step 2, 3, 4, 6, 9, 15, 18:
Diagnostic steps permitting the use of the TOYOTA
hand−held tester or TOYOTA brake− out−box.
−
DIAGNOSTICS AUTOMATIC TRANSMISSION
DI−129
296
Author: Date:
1996 LAND CRUISER (RM451U)
AUTOMATIC TRANSMISSION
HOW TO PROCEED WITH TROUBLESHOOTING
Troubleshoot in accordance with the procedure on the following page.
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