TOYOTA LAND CRUISER 1996 J80 Workshop Manual

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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BR1D7−01
−
BRAKE PARKING BRAKE
BR−39
1021
Author: Date:
1996 LAND CRUISER (RM451U)
PARKING BRAKE
COMPONENTS
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BR1D8−04
BR−40
−
BRAKE PARKING BRAKE
1996 LAND CRUISER (RM451U)
DISASSEMBLY
1. REMOVE REAR WHEEL
2. REMOVE REAR DISC BRAKE ASSEMBLY
(a) Remove the 2 mounting bolts and remove the disc brake assembly.
Torque: 88 N·m (900 kgf·cm, 65 ft·lbf)
(b) Suspend the disc brake assembly securely. Ensure that the hose is not stretched.
3. REMOVE DISC
Place the matchmarks on the disc and rear hub, and remove the
disc.
HINT:
If the disc cannot be removed easily, turn the shoe adjuster until
the wheel turns freely.
4. REMOVE TENSION SPRING
Using needle −nose pliers, remove the tension spring.
5. REMOVE SHOE RETURN SPRINGS
Using SST, remove the shoe return springs. SST 09717−20010
HINT:
Using SST, install the front shoe return spring and then install
the rear return spring. SST 09718−20010
6. REMOVE SHOE STRUT WITH SPRING
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−
BRAKE PARKING BRAKE
BR−41
1996 LAND CRUISER (RM451U)
7. REMOVE REAR SHOE, ADJUSTER AND TENSION
SPRING
(a) Slide out the rear shoe, and remove the rear shoe and ad-
juster.
(b) Remove the 2 shoe hold −down spring cups, spring and
pin.
(c) Remove the lower side tension spring.
8. REMOVE FRONT SHOE
(a) Slide out the front shoe.
(b) Remove the shoe 2 hold −down spring cups, springs and
pin.
(c) Disconnect the parking brake cable from the parking
brake shoe lever.
9. IF NECESSARY, REMOVE AND DISASSEMBLE PARKING BRAKE BELLCRANK ASSEMBLY
(a) Using a screwdriver, remove the C −washer.
(b) Remove the pin and disconnect the parking brake cable No.2 from the bellcrank.
(c) Remove the clip.
(d) Remove the pin and clip, then disconnect the parking
brake cable.
(e) Remove the 2 tension springs.
(f) Remove the 2 bolts and parking brake bellcrank assem- bly.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
(g) Remove the boot from parking brake bellcrank bracket.
(h) Using a screwdriver, remove the C −washer and pin.
(i) Remove the parking brake bellcrank from the bell crank bracket.
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BR1D9−02
BR0897
BR0828
R00343Clearance Shim
BR−42
−
BRAKE PARKING BRAKE
1996 LAND CRUISER (RM451U)
INSPECTION
1. INSPECT DISASSEMBLED PARTS
Inspect the disassembled parts for wear, rust or damage.
2. MEASURE BRAKE SHOE LINING THICKNESS
Using a ruler, measure the thickness of the shoe lining. Standard thickness: 4.0 mm (0.157 in.)
Minimum thickness: 1.0 mm (0.039 in.)
If the lining thickness is at the minimum thickness or less, or if
there is extremely uneven wear, replace the brake shoe.
3. MEASURE BRAKE DISC INSIDE DIAMETER
Using a vernier calipers, measure the inside diameter of the
disc. Standard inside diameter: 230 mm (9.06 in.)
Maximum inside diameter: 231 mm (9.09 in.)
Replace the disc if the inside diameter is at the maximum value
or more. Replace the disc or grind it with a lathe if the disc is
scored or is worn unevenly.
4. INSPECT PARKING BRAKE LINING AND DISC FOR PROPER CONTACT
Apply chalk to the inside surface of the disc, then grind down
the brake shoe lining to fit. If the contact between the disc and
the brake shoe lining is improper, repair it using a brake shoe
grinder or replace the brake shoe assembly.
5. MEASURE CLEARANCE BETWEEN PARKING BRAKE SHOE AND LEVER
Using a feeler gauge, measure the clearance.
Standard clearance: Less than 0.35 mm (0.0138 in.)
If the clearance is not within the specification, replace the shim
with one of the correct size.
Shim ThicknessShim Thickness
0.3 mm (0.012 in.)0.9 mm (0.035 in.)
0.6 mm (0.024 in.)
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−
BRAKE PARKING BRAKE
BR−43
1996 LAND CRUISER (RM451U)
6. IF NECESSARY, REPLACE SHIM
(a) Using a screwdriver, remove the C −washer.
(b) Remove the park ing brake shoe lever, and install the cor-
rect size shim.
(c) Using needle −nose pliers, install the parking brake shoe
lever with a new C −washer.
(d) Remeasure the clearance.
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BR1DA−01
BR−44
−
BRAKE PARKING BRAKE
1996 LAND CRUISER (RM451U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See
page BR−40 ).
NOTICE:
Apply high temperature grease and lithium soap base gly-
col grease to the parts indicated by the arrows (See page
BR−39 ).
1. ADJUST PARKING BRAKE SHOE CLEARANCE
(a) Disconnect the PKB cable from bellcrank and remove the 2 tension springs.
(b) Loosen the stopper bolt.
(c) Temporarily install the hub nuts.
(d) Remove the hole plug.
(e) Turn the adjuster and expand the shoes until the disc
locks.
(f) Return the adjuster 8 notches.
(g) Install the hole plug.
2. ADJUST BELLCRANK
(a) Pull the bellcrank until all play in the interior linkage is tak-
en up.
(b) Screw in the bellcrank adjusting bolt to where it contacts on the dust seal.
(c) Loosen it one turn, and lock it at that position with the lock nut.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
(d) Install the bellcrank spring.
(e) Connect the PKB cable to the bellcrank.
3. BEDDING DOWN PARKING BRAKE SHOES AND
DISC
(a) Drive the vehicle at about 50 km/h (31 mph) on a safe, lev-
el and dry road.
(b) With the parking brake release button pushed in, pull on the lever with 88 N (9 kgf, 19.8 lbf) of force.
(c) Drive the vehicle for about 400 meters (0.25 mile) in this condition.
(d) Repeat this procedure 2 or 3 times.
4. RECHECK AND ADJUST PARKING BRAKE LEVER TRAVEL
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BR1DC−04
R05477
A
−
BRAKE LOAD SENSING PROPORTIONING AND BY− PASS
VALVE (LSP & BV)BR−45
1027
Author: Date:
1996 LAND CRUISER (RM451U)
ON−VEHICLE INSPECTION
1. SET REAR AXLE LOAD
Rear axle load (include vehicle weight):
1,330 kg (2,932 lb)
2. INSTALL LSPV GAUGE (SST) AND BLEED AIR SST 09709−29018
3. RAISE FRONT BRAKE PRESSURE TO 7,845 kPa (80 kgf/cm
2, 1,138 psi) AND CHECK REAR BRAKE PRES-
SURE
Rear brake pressure:
5,984 ± 589 kPa (61 ± 6 kgf/cm
2, 869± 86 psi)
HINT:
The brake pedal should not be depressed twice and/or returned
while setting to the specified pressure. Read the value of rear
pressure 2 seconds a fter adjusting the specified fluid pressure.
4. IF NECESSARY, ADJUST FLUID PRESSURE
(a) Disconnect the No.2 shackle from the shackle bracket.
(b) Adjust the length of the No.2 shackle turning it. Low pressure − Lengthen A.
High pressure − Shorten A
Initial set: 90 mm (3.54 in.)
Adjusting range: 84 − 96 mm (3.31 − 3.78 in.)
HINT:
One turn of the No.2 shackle changes the fluid pressure by
about 98.1 kPa (1.0 kgf/cm
2, 14.2 psi).
(c) In event the pressure cannot be adjusted by No.2 shackle, raise or lower the valve body.
Low pressure − Lower
High pressure − Raise
(d) Torque the 2 nuts. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
(e) Adjust the length of the No.2 shackle again.
If it cannot be adjusted, inspect the valve housing.
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BR−46−
BRAKE LOAD SENSING PROPORTIONING AND BY− PASS
VALVE (LSP & BV)
1028
Author: Date:
1996 LAND CRUISER (RM451U)
5. IF NECESSARY, CHECK VALVE BODY
(a) Assemble the valve body in the uppermost position.
HINT:
When the brakes are applied, the piston will move down about
1 mm (0.039 in.). Even at this time, the piston should not make
contact with or move the load sensing spring.
(b) In this position, check the rear brake pressure.
Front brake pressure
kPa (kgf/cm2, psi)
Rear brake pressure kPa (kgf/cm2, psi)
3,434 (35, 498)3,434 (35, 498)
5,396 (55, 783)3,630 − 4,218
(37 − 43, 527 − 612)
9,810 (100, 1,424)4,513 − 5,494
(46 − 56, 655 − 797)
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BR1DB−01
−
BRAKE LOAD SENSING PROPORTIONING AND BY− PASS
VALVE (LSP & BV)BR−47
1996 LAND CRUISER (RM451U)
LOAD SENSING PROPORTIONING AND BY −PASS VALVE
(LSP & BV)
COMPONENTS
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