TOYOTA RAV4 1996 Service Repair Manual

BR02G−04
BR−2
− BRAKETROUBLESHOOTING
1996 RAV4 (RM447U)
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
Lower pedal or spongy pedal
1. Brake system (Fluid leaks)
2. Brake system (Air in)
3. Piston seals (Worn or damaged)
4. Rear Brake shoe clearance (Out of adjustment)
5. Master cylinder (Faulty)
6. Booster push rod (Out of adjustment)DI−282
−
BR−23
BR−33
BR−9
BR−19
Brake drag
1. Brake pedal freeplay (Minimal)
2. Parking brake lever travel (Out of adjustment)
3. Parking brake wire (Sticking)
4. Rear brake shoe clearance (Out of adjustment)
5. Pad or lining (Cracked or distorted)
6. Piston (Stuck)
7. Piston (Frozen)
8. Anchor or return spring (Faulty)
9. Booster push rod (Out of adjustment)
10. Booster system (Vacuum leaks)
11. Master cylinder (Faulty)BR−6
BR−8
−
BR−33
BR−20
BR−29
BR−23
BR−23
BR−29
BR−29
BR−19
BR−16
BR−9
Brake pull
1. Piston (Stuck)
2. Pad or lining (Oily)
3. Piston (Frozen)
4. Disc (Scored)
5. Pad or lining (Cracked or distorted)BR−23
BR−20
BR−29
BR−23
BR−29
BR−20
BR−20
BR−29

− BRAKETROUBLESHOOTING
BR−3
1996 RAV4 (RM447U) Hard pedal but brake inefficient
1. Brake system (Fluid leaks)
2. Brake system (Air in)
3. Pad or lining (Worn)
4. Pad or lining (Cracked or distorted)
5. Rear brake shoe clearance (Out of adjustment)
6. Pad or lining (Oily)
7. Pad or lining (Glazed)
8. Disc (Scored)
9. Booster push rod (Out of adjustment)
10. Booster system (Vacuum leaks)DI−282
−
BR−20
BR−29
BR−20
BR−29
BR−33
BR−20
BR−29
BR−20
BR−29
BR−23
BR−19
BR−16
Noise from brake
1. Pad or lining (Cracked or distorted)
2. Installation bolt (Loose)
3. Disc (Scored)
4. Pad support plate (Loose)
5. Sliding pin (Worn)
6. Pad or lining (Dirty)
7. Pad or lining (Glazed)
8. Anchor or return spring (Faulty)
9. Anti−squeal shim (Damage)
10. Hold−down spring (Damage)BR−20
BR−29
BR−23
BR−23
BR−23
BR−23
BR−20
BR−29
BR−20
BR−29
BR−29
BR−20
BR−29

R10712
BR02H−02
R10713
R10714
R00252
BR−4
− BRAKEBRAKE FLUID
1996 RAV4 (RM447U)
BRAKE FLUID
BLEEDING
HINT:
If any work is done on the brake system or air in the brake lines
is suspected, 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
Fluid: SAEJ1703 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 master cylinder of the air.
(a) Disconnect the brake lines from the master cylinder.
(b) Slowly depress the brake pedal and hold it.
(c) Block off the outlet plug with your finger and release the
brake pedal.
(d) Repeat (b) and (c) 3 or 4 times.
3. BLEED BRAKE LINE
(a) Connect the vinyl tube to the caliper or wheel cylinder.
(b) Depress the brake pedal several times, then loosen the
bleeder plug with the pedal held down.
(c) At the point when fluid stops coming out, tighten the
bleeder plug, then release the brake pedal.
(d) Repeat (b) and (c) until all the air in the fluid has been bled
out.
(e) Repeat the above procedure to bleed the brake line of the
air for each wheel.

− BRAKEBRAKE FLUID
BR−5
1996 RAV4 (RM447U)
4. CHECK FLUID LEVEL IN RESERVOIR
Check the fluid level and add fluid if necessary.
Fluid: SAEJ1703 or FMVSS No.116 DOT3

R10851
Pedal Height Push RodStop Light
Switch
BR1DV−01
BR4980
R00935
Pedal Freeplay BR−6
− BRAKEBRAKE PEDAL
1996 RAV4 (RM447U)
BRAKE PEDAL
ON−VEHICLE INSPECTION
1. CHECK PEDAL HEIGHT
Pedal height from asphalt sheet:
157.1 − 167.1 mm (6.185 − 6.579 in.)
If the pedal height is incorrect, adjust it.
2. IF NECESSARY, ADJUST PEDAL HEIGHT
(a) Disconnect the connector from the stop light switch.
(b) Loosen the stop light switch lock nut and remove the stop
light switch.
(c) Loosen the push rod lock nut.
(d) Adjust the pedal height by turning the pedal push rod.
(e) Tighten the push rod lock nut.
Torque: 25 N·m (260 kgf·cm, 19 ft·lbf)
(f) Install the stop light switch and turn it until it lightly con-
tacts with the pedal stopper.
(g) Turn the stop light switch back one turn.
(h) Check the clearance (A) between stop light switch and
pedal.
Clearance: 0.5 − 2.4 mm (0.020 − 0.094 in.)
(i) Tighten the stop light switch lock nut.
(j) Connect the connector to the stop light switch.
(k) Check that the stop lights come on when the brake pedal
is depressed, and go off when the brake pedal is re-
leased.
(l) After adjusting the pedal height, check the pedal freeplay.
HINT:
If clearance (A) between the stop light switch and the brake
pedal stopper has been adjusted correctly, the pedal freeplay
will meet the specifications.
3. CHECK PEDAL FREEPLAY
(a) Stop the engine and depress the brake pedal several
times until there is no more vacuum left in the booster.
(b) Push in the pedal by hand until the resistance begins to
be felt, then measure the distance, as shown.
Pedal freeplay: 1 − 6 mm (0.04 − 0.24 in.)

R00934
Pedal Reverse
Distance
− BRAKEBRAKE PEDAL
BR−7
1996 RAV4 (RM447U)
HINT:
The freeplay to the 1st point of resistance is due to the play be-
tween the clevis and pin. It is 1 − 3 mm (0.04 − 0.12 in.) on the
pedal.
If incorrect, check the stop light switch clearance. If the clear-
ance is OK, then troubleshoot the brake system.
4. CHECK PEDAL RESERVE DISTANCE
(a) Release the parking brake.
(b) With the engine running, depress the pedal and measure
the pedal reserve distance, as shown.
Pedal reserve distance from asphalt sheet at 490 N
(50 kgf, 110.2 lbf): More than 75 mm (2.95 in.)
If the reserve distance is incorrect, troubleshoot the brake sys-
tem.

R10698
BR02J−10
R10730
Lock Nut
Adjusting
Nut BR−8
− BRAKEPARKING BRAKE LEVER
1996 RAV4 (RM447U)
PARKING BRAKE LEVER
ON−VEHICLE INSPECTION
1. CHECK PARKING BRAKE LEVER TRAVEL
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 lbf):
5 − 8 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−33.
(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.

BR0M2−02
− BRAKEBRAKE MASTER CYLINDER
BR−9
1996 RAV4 (RM447U)
BRAKE MASTER CYLINDER
COMPONENTS

W01346
BR−10
− BRAKEBRAKE MASTER CYLINDER
1996 RAV4 (RM447U)

BR02L−02
W01806
SST
W01807
− BRAKEBRAKE MASTER CYLINDER
BR−11
1996 RAV4 (RM447U)
REMOVAL
1. DISCONNECT LEVEL WARNING SWITCH CONNEC-
TOR
2. DRAW OUT FLUID WITH SYRINGE
NOTICE:
Do not let brake fluid remain on a painted surface. Wash it
off immediately.
3. DISCONNECT R/B NO.2
Remove the 2 bolts and disconnect R/B No.2.
4. REMOVE AIR CLEANER CAP WITH AIR CLEANER
HOSE
5. w/o ABS:
DISCONNECT BRAKE LINES
Using SST, disconnect the 5 brake lines from the master cylin-
der and 3−way.
SST 09023−00100
Torque: 15 N·m (155 kgf·cm, 11 ft·lbf)
6. w/ ABS:
DISCONNECT BRAKE LINES
Using SST, disconnect the 2 brake lines from the master cylin-
der.
SST 09023−00100
Torque: 15 N·m (155 kgf·cm, 11 ft·lbf)
7. M/T:
DISCONNECT CLUTCH RESERVOIR HOSE
8. w/o ABS:
REMOVE MASTER CYLINDER
Remove the 2 nuts and pull out the master cylinder, 3−way and
gasket.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
9. w/ ABS:
REMOVE MASTER CYLINDER
Remove the 2 nuts, and pull out the master cylinder and gasket.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)