TOYOTA RAV4 1996 Service Repair Manual

4. Refill brake fluid reservoir as necessary. Repeat step 3 until air is no longer discharged. On RAV4,
tighten front bleeder screw to 69 INCH lbs. (7.8 N.m), and tighten rear bleeder screw to 74 INCH lbs.
(8.3 N.m). On Sienna, tighten bleeder screw to 74 INCH lbs. (8.3 N.m). Tighten bleeder screw to 97
INCH lbs. (11 N.m) on Land Cruiser, Tacoma, Tundra & 4Runner. Ensure fluid leakage is not present.
Add fluid to reservoir. Repeat procedure for remaining wheels.
ADJUSTMENTS
BRAKE PEDAL HEIGHT
1. Brake pedal height is measured from face of pedal pad to asphalt sheet under carpet. To adjust clearance,
loosen stoplight switch and lock nut on brake push rod. See Fig. 1
.
2. Adjust pedal height by turning push rod. See BRAKE PEDAL SPECIFICATIONS
table. After setting
pedal height, tighten lock nut on push rod. Adjust stoplight switch and tighten switch lock nut. See
STOPLIGHT SWITCH
.
Fig. 1: Measuring Brake Pedal Height & Free Play

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
BRAKE PEDAL SPECIFICATIONS
ApplicationFree Play - In. (mm)Pedal Height - In. (mm)
Land Cruiser.04-.24 (1-6)7.23-7.63 (184-194)

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BRAKE PEDAL FREE PLAY
1. Brake pedal free play is distance brake pedal travels before feeling resistance with engine stopped. To
check pedal free play, depress brake pedal several times to exhaust vacuum from booster.
2. Depress pedal and measure travel until initial resistance is felt. See BRAKE PEDAL
SPECIFICATIONS table. If free play is not within specification, adjust by turning push rod. See Fig. 1.
BRAKE PEDAL RESERVE DISTANCE
1. Pedal reserve distance is measured from face of pedal pad to asphalt sheet under carpet with brakes
applied. Measure reserve distance with engine running and weight of 110 lbs. (50 kg) applied against
pedal.
2. If measured reserve distance is less than specification, inspect brake system. See BRAKE PEDAL
MINIMUM RESERVE DISTANCE SPECIFICATIONS table.
BRAKE PEDAL MINIMUM RESERVE DISTANCE SPECIFICATIONS
LOAD-SENSING PROPORTIONING VALVE (LSPV) & BY-PASS VALVE (BPV)
PARKING BRAKE
Lever Stroke Adjustment
1. To check parking brake adjustment, pull on parking brake lever with weight of 66 lbs. (27 kg) on Sienna
and 44 lbs. (20 k
g) on all other models. Count number of notches (clicks) until parking brake is fully
RAV4.04-.24 (1-6)6.19-6.58 (157-167)
Sienna.04-.24 (1-6)6.28-6.67 (160-170)
Tacoma.12-.24 (3-6)6.09-6.48 (155-165)
Tundra.04-.24 (1-6)6.46-6.85 (164-174)
4Runner.12-.24 (3-6)6.34-6.74 (161-171)
ApplicationIn. (mm)
Land Cruiser4.57 (116)
RAV42.95 (75)
Sienna3.78 (96)
Tacoma2.83 (72)
Tundra3.74 (95)
4Runner2.83 (72)
NOTE: See LOAD
-SENSING PROPORTIONING VALVE (LSPV) & BY-PASS VALVE (BPV)
under TESTING.
NOTE: Rear brakes must be correctly adjusted before adjusting parking brake. See
REAR BRAKE DRUM
under REMOVAL & INSTALLATION.

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applied. See PARKING BRAKE LEVER STROKE SPECIFICATIONS table. Adjust parking brake
if travel is not within specification.
PARKING BRAKE LEVER STROKE SPECIFICATIONS
2. On Land Cruiser, loosen lock nut, and rotate turnbuckle until lever travel is correct. Tighten lock nut.
3. On RAV4, remove rear console box. Loosen lock nut and turn adjusting nut until lever travel is correct.
Tighten lock nut. Install rear console box.
4. On Sienna, release parking brake pedal. Loosen lock nut. Hold equalizer and turn adjusting nut until
pedal travel is correct.
5. On Tacoma (2WD) Tundra (2WD), tighten adjusting nut until travel is correct. Tighten lock nut. Confirm
that rear brakes are not dragging.
6. On Tacoma (4WD) and Tundra (4WD), tighten one of the adjusting nuts of the intermediate lever.
Loosen other nut until travel is correct. Tighten 2 adjusting nuts. Confirm that bell crank stopper screw
comes into contact with backing plate.
7. On 4Runner, remove console box. Loosen adjusting nut until lever travel is correct. Tighten lock nut.
Install console box.
PARKING BRAKE SHOES
Land Cruiser (With Rear Disc Brakes)
Raise and support rear of vehicle. Release parking brake. Remove adjustment hole plug from backing plate.
Turn adjuster until parking brake shoes lock wheel. Back adjuster off 8 notches. Install hole plug.
POWER BRAKE UNIT PUSH ROD
1. Install adjusting gauge on master cylinder with master cylinder gasket in place. Lower adjusting gauge
pin until pin slightly touches master cylinder piston. Perform STEP 1. See Fig. 2
. Turn adjusting gauge
upside down and install on power brake unit.
2. Measure clearance between power brake unit push rod and adjusting gauge pin head. Measured clearance
should be zero on all models except Sienna. On Sienna, clearance should be .014" (.35 mm). Perform
STEP 2. See Fig. 2
. If clearance is not as specified, adjust brake booster push rod length until push rod
li
ghtly touches adjusting gauge pin head.
ApplicationNotches
Land Cruiser4-6
RAV45-8
Sienna3-5
Tacoma12-18
Tundra5-8
4Runner7-9

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Fig. 2: Adjusting Brake Booster Push Rod
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
REAR DRUM BRAKE SHOES
To set initial lining-to-drum clearance, raise and support rear of vehicle. Release parking brake. Remove rear
wheels and brake drums. Measure brake drum inside diameter and brake lining diameter. Measured clearance
between linings and braking surface of drum should be .024" (.60 mm) on RAV4 and Tacoma, or .020" (.50
mm) on all other models. Turn brake adjuster to obtain specified clearance. Install brake drum and wheel and
adjust brakes (if necessary).
STOPLIGHT SWITCH
Remove lower instrument panel and air duct (if necessary). Loosen lock nuts. Turn switch until clearance
between threaded end of switch and pedal stop is .02-.09" (.5-2.3 mm), on all models except Land Cruiser.
Clearance should be .039" (1.0 mm) on Land Cruiser. See Fig. 1
. Check brake pedal height and brakelight
operation.
TESTING
POWER BRAKE UNIT (EXCEPT LAND CRUISER)
Operational Check
Depress brake pedal several times with engine off. There should be no change in pedal reserve distance.
NOTE: All rear drum brakes have a self-adjuster which is activated when brake pedal is
applied with vehicle traveling in reverse.

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Depress brake pedal and start engine. If pedal goes down slightly, operation is normal.
Air Tightness Check
1. Start engine and run for 1-2 minutes, then turn engine off. Depress brake pedal several times slowly. If
pedal goes down farthest on first time, but gradually rises after second or third time, power brake unit is
airtight.
2. With engine stopped, depress brake pedal several times using normal pressure. Pedal should be low when
first depressed. On consecutive applications, pedal height should gradually rise. If pedal height does not
increase, check for air leaks.
LOAD-SENSING PROPORTIONING VALVE (LSPV) & BY-PASS VALVE (BPV)
Tacoma & Tundra
1. For testing purposes, rear axle is loaded to a specified weight. Set total rear axle weight to specified
amount. See LSPV REAR AXLE TEST WEIGHT
table.
2. Attach pressure gauge set to front caliper and rear wheel cylinder or caliper. Bleed air from system. See
BLEEDING BRAKE SYSTEM
. Depress brake pedal until front pressure is as specified. See LSPV
PRESSURE SPECIFICATIONS table. Wait 2 seconds and record rear pressure reading.
LSPV REAR AXLE TEST WEIGHT
LSPV PRESSURE SPECIFICATIONS NOTE: DO NOT depress brake pedal more than once or release pedal while
setting pressure on front gauge.
ApplicationLbs. (kg)
Tacoma
2WD1543 (700)
4WD1874 (850)
Tundra
V6
Engine
(5UZ-
FE)2205 (1000)
V8
Engine
(2UZ-
FE)2315 (1050)
4Runner2033 (922)
Application
Front Pressure - psi
(kg/cm
2 )
Rear Pressure - psi
(kg/cm
2 )
Tacoma

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3. Adjust rear pressure by changing length of No. 2 shackle (if necessary). See Fig. 3 . To increase rear
pressure reading, increase distance "A". To decrease rear pressure reading, decrease distance "A".
4. Repeat pressure tests after adjusting shackle length. If rear pressures fail specification after adjustment,
reposition valve body. Raise valve body if rear pressures are too high, lower valve body if rear pressures
are too low.
5. Ensure No. 2 shackle length is within adjustment range. If shackle is removed or replaced, adjust No. 2
shackle to standard length. See NO. 2 SHACKLE LENGTH SPECIFICATIONS
table.
Fig. 3: Measuring LSPV No. 2 Shackle Length (Tacoma Shown; Tundra Similar)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
NO. 2 SHACKLE LENGTH SPECIFICATIONS
2WD1138 (80)640-782 (45-55)
4WD1138 (80)569-711 (40-50)
Tundra1138 (80)670-812 (47-57)
4Runner996 (70)393-563 (28-40)
Application
Standard Length - In.
(mm)Adjustment Range - In.
(mm)
Tacoma

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6. If pressures cannot be adjusted to specification, check valve housing. Position valve body in uppermost
position. Apply brakes and record rear brake pressures. See VALVE BODY ADJUSTMENT
PRESSURE SPECIFICATIONS (TACOMA & TUNDRA) table. If measured value does not meet
specification, replace valve assembly.
VALVE BODY ADJUSTMENT PRESSURE SPECIFICATIONS (TACOMA & TUNDRA)
4Runner
1. For testing purposes, rear axle is loaded to a specified weight. Set total rear axle weight to specified
amount. See LSPV REAR AXLE TEST WEIGHT
table.
2. Attach pressure gauge set to front caliper and rear wheel cylinder. Bleed air from system. See
BLEEDING BRAKE SYSTEM
. Depress brake pedal until front pressure is as specified. See LSPV
PRESSURE SPECIFICATIONS table. Wait 2 seconds and record rear pressure reading.
3. Adjust rear pressure by changing length "A" or "B". See Fig. 4
. To increase rear pressure reading,
decrease distance "A" or "B". To decrease rear pressure reading, increase distance "A" or "B". If valve
cannot be adjusted to specification, replace valve assembly.
2WD3.07 (78)2.83-3.31 (72-84)
4WD4.72 (120)4.49-4.96 (114-126)
Tundra4.72 (120)4.41-5.04 (112-128)
Application
Front Pressure - psi
(kg/cm
2 )
Rear Pressure - psi
(kg/cm
2 )
Tacoma
2WD
1st Reading285 (20)285 (20)
2nd Reading570 (40)327-384 (23-27)
3rd Reading998 (70)412-512 (29-36)
4WD
1st Reading213 (15)213 (15)
2nd Reading570 (40)256-313 (18-22)
3rd Reading998 (70)320-420 (23-30)
Tundra
1st Reading213 (15)213 (15)
2nd Reading569 (40)263-377 (19-27)
3rd Reading1990 (140)682-852 (48-60)
NOTE: DO NOT depress brake pedal more than once or release pedal while
setting pressure on front gauge.
NOTE: To adjust pressure, turning adjusting nut one complete turn (360 degrees) will
change pressure 14 psi (1.0 kg/cm
2 ). If adjusting nut is moved up or

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Fig. 4: Making LSPV Pressure Adjustment (4Runner)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
PROPORTIONING VALVE
RAV4 & Sienna
Attach and bleed pressure gauge set. Raise master cylinder pressure and check rear wheel pressure. See
PROPORTIONING VALVE PRESSURE SPECIFICATIONS (RAV4 & SIENNA)
table. When inspecting
fluid pressure, check left front and right rear together, then check right front and left rear together. If rear
cylinder pressure is incorrect, replace ABS actuator. See appropriate ANTI-LOCK article in BRAKES. Remove
pressure gauge set. Bleed brake system and check for leaks.
PROPORTIONING VALVE PRESSURE SPECIFICATIONS (RAV4 & SIENNA) down .04" (1.0 mm), pressure will change 6 psi (.4 kg/cm
2 ).
ApplicationMaster Cylinder
Pressure - psi (kg/cm2)Rear Wheel
Cylinder Pressure -
psi (kg/cm2)
RAV4
Low Pressure Reading356 (25)356 (25)
High Pressure Reading1138 (80)551 (39)

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PROPORTIONING VALVE & BY-PASS VALVE
Land Cruiser (Models Without Traction Control ABS)
1. Turn ignition off. Depress brake pedal at least 40 times. Install proportioning valve gauge to front brake
caliper brake line connection and to rear brake caliper brake line connection. Bleed air from gauges and
lines.
2. Turn ignition to ON position and wait until pump motor has stopped. Raise front brake caliper pressure
and check rear brake caliper pressure by depressing brake pedal and checking fluid pressure on gauges.
3. If rear brake caliper pressure is incorrect, replace hydraulic brake booster. See HYDRAULIC BRAKE
BOOSTER under REMOVAL & INSTALLATION.
PROPORTIONING VALVE & BY-PASS VALVE PRESSURE SPECIFICATIONS (LAND CRUISER)
REMOVAL & INSTALLATION
FRONT DISC BRAKE PADS
Removal & Installation (Land Cruiser)
Raise and support vehicle. Remove front wheel. Remove clip, 2 pins, 2 pad retainer clips, pads, anti-squeal
shims and pad retainers. See Fig. 5
. Remove enough brake fluid from master cylinder so overflow will not
occur as piston is seated. Seat pistons using a hammer handle or equivalent. Slide NEW pads and anti-rattle
shims into caliper. Check reservoir fluid level. To install, reverse removal procedure. Tighten lower caliper bolt
to specification. See TORQUE SPECIFICATIONS
.
Sienna
Low Pressure Reading427 (30)427 (30)
High Pressure Reading1138 (80)711 (50)
Front Brake Caliper Pressure - psi (kg/cm2)Rear Brake Caliper Pressure - psi (kg/cm2)
327 (23)356 (25)
640 (45)484-540 (34-38)
1138 (80)754 (53)
NOTE: Location and number of anti-rattle springs, anti-squeal shims, pad support and
guide plates vary between models. Note component locations during removal
process for reassembly reference. Tacoma, Tundra and 4Runner with 4WD use
dual-piston calipers; other models use single-piston calipers.
NOTE: Pushing piston into caliper bore will force fluid back into master cylinder
reservoir. Remove reservoir cap when compressing caliper piston.

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Fig. 5: Exploded View Of Front Brake Caliper Assembly (Land Cruiser)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal & Installation (RAV4 & Sienna)
1. Raise and support vehicle. Remove front wheel. Hold sliding pin on bottom and loosen installation bolt.
Remove installation bolt and rotate caliper upward. Suspend caliper aside with wire.

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