TOYOTA LAND CRUISER 1996 J80 Workshop Manual

BR4774
BR1CG−01
BR4775
BR−8
−
BRAKE PARKING BRAKE LEVER
990
Author: Date:
1996 LAND CRUISER (RM451U)
PARKING BRAKE LEVER
ON−VEHICLE INSPECTION
1. CHECK THAT PARKING BRAKE LEVER TRAVEL IS
CORRECT
Pull the parking brake lever all the way up, and count the num-
ber of clicks.
Parking brake lever travel at 196 N (20 kgf, 44.1 lbf):
7 − 9 clicks
If incorrect, adjust the parking brake.
2. IF NECESSARY, ADJUST PARKING BRAKE
HINT:
Before adjusting the parking brake, make sure that the rear
brake shoe clearance has been adjusted. For shoe clearance
adjustment (See page BR−42).
(a) Remove the rear console box.
(b) Loosen the lock nut and turn the adjusting nut until the le-
ver travel is correct.
(c) Tighten the lock nut.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
(d) Install the rear console box.
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BR1CH-01
-
BRAKE BRAKE MASTER CYLINDER
BR-9
1996 LAND CRUISER (RM451U)
BRAKE MASTER CYLINDER
COMPONENTS
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BR1CI-01
R13497
R13591
BR-10
-
BRAKE BRAKE MASTER CYLINDER
1996 LAND CRUISER (RM451U)
REMOVAL
1. DISCONNECT LEVEL WARNING SWITCH CONNEC- TOR
2. TAKE OUT FLUID WITH SYRINGE
NOTICE:
Do not let brake fluid remain on a painted surface. Wash it
off immediately.
3. DISCONNECT BRAKE LINES
Using SST, disconnect the 4 brake lines from the master cylin-
der and 3-way. SST 09023-00100
Torque: 15 N´m (155 kgf´cm, 11 ft´lbf)
4. REMOVE MASTER CYLINDER
(a) Remove the 4 nuts. Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)
(b) Remove the 3-way, check valve bracket, wire harness clamp and bracket.
(c) Pull out the master cylinder and gasket.
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BR1CJ-01
R12236
A
-
BRAKE BRAKE MASTER CYLINDER
BR-1 1
1996 LAND CRUISER (RM451U)
DISASSEMBLY
1. REMOVE RESERVOIR
(a) Remove the set screw and pull out the reservoir.
Torque: 1.7 N´m (17.5 kgf´cm, 15.2 in.´lbf)
(b) Remove the cap and strainer from the reservoir.
2. REMOVE 2 GROMMETS
3. REMOVE BOLT AND CLAMP FROM CYLINDER BODY
4. PLACE CYLINDER IN VISE
5. REMOVE PISTON STOPPER BOLT
Using a screwdriver, push the pistons in all the way and remove
the piston stopper bolt and gasket.
HINT:
Tape the screwdriver tip before use. Torque: 10 N´m (100 kgf´cm, 7 ft´lbf)
6. REMOVE 2 PISTONS AND SPRINGS
(a) Push in the piston with a screwdriver and remove the snap ring with snap ring pliers.
HINT:
Tape the screwdriver tip before use.
(b) Remove the No.1 piston and spring by hand, pulling straight out, not at an angle.
NOTICE:
If pulled out and installed at an angle, there is a possibly
that the cylinder bore could be damaged.
NOTICE:
Be careful not to damage the rubber lips on the pistons.
(c) Place a rag and 2 wooden blocks on the work table, and lightly tap the cylinder flange against the block edges until
the No.2 piston drops out of the cylinder.
HINT:
Make sure that the distance (A) from the rag to the top of the
blocks is at least 100 mm (3.94 in.).
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BR1CK-01
BR-12
-
BRAKE BRAKE MASTER CYLINDER
1996 LAND CRUISER (RM451U)
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.
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BR1CL-01
-
BRAKE BRAKE MASTER CYLINDER
BR-13
1996 LAND CRUISER (RM451U)
REASSEMBLY
Reassembly is in the reverse order of disassembly.
NOTICE:
Apply lithium soap base glycol grease to the rubber parts indicated by t\
he arrows
(See page BR-9 ).
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BR1CM-01
BR-14
-
BRAKE BRAKE MASTER CYLINDER
1996 LAND CRUISER (RM451U)
INSTALLATION
Installation is in the reverse order of removal (See page BR-9).
HINT:

Before installation, adjust length of brake booster push rod (See page \
BR-18).

After installation, fill brake reservoir with brake fluid, bleed brake s\
ystem (See page BR-4).

Check for leaks, check and adjust brake pedal (See page BR-6).
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BR1CN-01
BR2238
-
BRAKE BRAKE BOOSTER ASSEMBLY
BR-15
1996 LAND CRUISER (RM451U)
BRAKE BOOSTER ASSEMBLY
OPERATION
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 the 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 the engine with the pedal depressed. If there is no
change in the pedal reserve travel after holding the pedal
for 30 seconds, the booster is air tight.
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BR1CO-01
BR-16
-
BRAKE BRAKE BOOSTER ASSEMBLY
1996 LAND CRUISER (RM451U)
COMPONENTS
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BR2237
BR1NM−01
BR2238
−
BRAKE BRAKE BOOSTER ASSEMBLY
BR−17
999
Author: Date:
1996 LAND CRUISER (RM451U)
BRAKE BOOSTER ASSEMBLY
OPERATION
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 the 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 the engine with the pedal depressed. If there is no
change in the pedal reserve travel after holding the pedal
for 30 seconds, the booster is air tight.
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