TOYOTA LAND CRUISER 1998 Factory Repair Manual

BR0JL-03
F04972
Z09007
170mm
(6.70in)50mm
(1.97in)
30mm
(1.18in)
BR0213
F04973
BR-20
- BRAKEFRONT BRAKE CALIPER
2156 Author
: Date
:
2004 LAND CRUISER (RM1071U)
DISASSEMBLY
1. REMOVE CYLINDER BOOT SET RINGS AND CYL-
INDER BOOTS
Using a screwdriver, remove the 4 cylinder boot set rings and
4 cylinder boots from the caliper.
2. REMOVE PISTONS FROM CYLINDER
(a) Prepare the wooden plate to hold the pistons.
(b) Place the plate between the pistons and insert a pad at
one side.
(c) Use compressed air to remove the pistons alternately
from the cylinder.
CAUTION:
Do not place your fingers in front of the piston when using
compressed air.
3. REMOVE PISTON SEALS FROM BRAKE CYLINDER
Using a screwdriver, remove the 4 piston seals from the cylin-
der.

F04980
BR0JM-06
F04981
F04982
- BRAKEFRONT BRAKE CALIPER
BR-21
2157 Author
: Date
:
2004 LAND CRUISER (RM1071U)
INSPECTION
1. MEASURE PAD LINING THICKNESS
Using a ruler, measure the pad lining thickness.
Standard thickness: 11.5 mm (0.453 in.)
Minimum thickness: 1.0 mm (0.039 in.)
Replace the pad if the pad's thickness is at the minimum or if
it shows signs of uneven wear.
2. MEASURE DISC THICKNESS
Using a micrometer, measure the disc thickness.
Standard thickness: 32.0 mm (1.260 in.)
Minimum thickness: 30.0 mm (1.181 in.)
Replace the disc if the thickness of the disc is at the minimum
thickness or less. Replace the disc or grind it on a lathe if it is
scored or is worn unevenly.
3. MEASURE DISC RUNOUT
Using a dial indicator, measure the disc runout at a position 10
mm (0.39 in.) from the out side edge.
Maximum disc runout: 0.07 mm (0.0028 in.)
If the bearing play and axle hub runout are not abnormal, re-
place the disc or grind it on an ºOn-Car brake latheº.
HINT:
Before measuring the runout, confirm that the front bearing pre-
load is within the specification (See page SA-16).
4. IF NECESSARY, REPLACE DISC
(a) Remove the front axle hub (See page SA-12).
(b) Remove the disc from the axle hub (See pageSA-13).
(c) Install a new disc and torque the 5 bolts.
Torque: 74 N´m (750 kgf´cm, 54 ft´lbf)
(d) Install the axle hub and adjust the front bearing preload
(See page SA-16).

BR0JO-06
- BRAKEFRONT BRAKE CALIPER
BR-23
2159 Author
: Date
:
2004 LAND CRUISER (RM1071U)
INSTALLATION
Installation is in the reverse order of removal (See page BR-19).
HINT:

After installation, fill the brake reservoir with brake fluid and bleed brake system (See page BR-4).

Check for leaks.

BR0JN-04
BR-22
- BRAKEFRONT BRAKE CALIPER
2158 Author
: Date
:
2004 LAND CRUISER (RM1071U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page BR-20).
HINT:
Apply lithium soap base glycol grease to the parts indicated by the arrows (See page BR-18).

BR0TA-04
F04974
F04975
- BRAKEFRONT BRAKE CALIPER
BR-19
2155 Author
: Date
:
2004 LAND CRUISER (RM1071U)
REMOVAL
1. REMOVE FRONT WHEEL
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
2. DISCONNECT BRAKE LINE
(a) Remove the union bolt and 2 gaskets from the caliper,
then disconnect the flexible hose from the caliper.
Torque: 30 N´m (310 kgf´cm, 22 ft´lbf)
(b) Use a container to catch the brake fluid as it drains out.
3. REMOVE CALIPER
Remove the 2 mounting bolts and remove the caliper.
Torque: 123 N´m (1,250 kgf´cm, 90 ft´lbf)
4. REMOVE CLIP AND 2 PINS
5. REMOVE 2 PAD RETAINER CLIPS
6. REMOVE 2 PADS, ANTI-SQUEAL SHIMS AND PAD
RETAINERS

BR0JH-03
F04971
Anti-squeal Shim
Pin Pad Retainer Clip
Clip
Anti-squeal Shim
Pad Retainer Pad Retainer
Outer Pad Inner Pad
Disc brake grease
- BRAKEFRONT BRAKE PAD
BR-15
2151 Author
: Date
:
2004 LAND CRUISER (RM1071U)
FRONT BRAKE PAD
COMPONENTS

BR0JI-1 1
F04993
F04994
F04995
BR-16
- BRAKEFRONT BRAKE PAD
2152 Author
: Date
:
2004 LAND CRUISER (RM1071U)
REPLACEMENT
1. REMOVE FRONT WHEEL
2. INSPECT PAD LINING THICKNESS
Check the pad thickness through the caliper inspection hole
and replace the pads if they are not within the specification.
Minimum thickness: 1.0 mm (0.039 in.)
3. REMOVE CLIP AND 2 PINS
4. REMOVE 2 PAD RETAINER CLIPS
5. REMOVE 2 PADS, ANTI-SQUEAL SHIMS AND PAD
RETAINERS
NOTICE:
The pad retainer clip and clip 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.
6. CHECK DISC THICKNESS AND DISC RUNOUT
(See page BR-21)
7. INSTALL NEW PADS
NOTICE:
When replacing worn pads, the anti-squeal shims must be
replaced together with the pad.
(a) Draw out a small amount of brake fluid from the reservoir.
(b) Press in the piston with a hammer handle or an equiva-
lent.
HINT:

Always change the pads on one wheel at a time as there
is a possibility of opposite piston fling out.

If the piston is difficult to push in, loosen the bleeder plug
and push in the piston while letting some brake fluid es-
cape.
(c) Install the 2 pad retainers to each caliper piston.
(d) Install the anti-squeal shim to each pad.
HINT:
Apply disc brake grease to both sides of the anti-squeal shims
(See page BR-15).
(e) Install the 2 pads.
HINT:
Apply disc brake grease to the pads indicated by the arrows
(See page BR-15).

- BRAKEFRONT BRAKE PAD
BR-17
2153 Author
: Date
:
2004 LAND CRUISER (RM1071U)
NOTICE:
There should be no oil or grease adhering to the friction
surfaces of the pads or the disc.
8. INSTALL 2 PAD RETAINER CLIPS AND 2 PINS
9. INSTALL CLIP
10. INSTALL FRONT WHEEL
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
11. DEPRESS BRAKE PEDAL SEVERAL TIMES
12. CHECK THAT FLUID LEVEL IS AT MAX LINE

BR0K1-06
F05023
N´m (kgf´cm, ft´lbf) : Specified torque
Front Speed Sensor
8.0 (82, 71 in.´lbf)
13 (130, 9)
13 (130, 9)
BR-68
- BRAKEFRONT SPEED SENSOR
2204 Author
: Date
:
2004 LAND CRUISER (RM1071U)
FRONT SPEED SENSOR
COMPONENTS

BR0K3-13
BR-70
- BRAKEFRONT SPEED SENSOR
2206 Author
: Date
:
2004 LAND CRUISER (RM1071U)
INSTALLATION
Installation is in the reverse order of removal (See page BR-69).
HINT:
After installation, check the speed sensor signal (See page DI-505).