TOYOTA RAV4 1996 Service Repair Manual

BR02M−02
R09358
R09359
R12236
A BR−12
− BRAKEBRAKE MASTER CYLINDER
1996 RAV4 (RM447U)
DISASSEMBLY
1. REMOVE RESERVOIR
(a) Remove the set screw and pull out the reservoir.
Torque:
1.8 N·m (18 kgf·cm, 16 in.·lbf)
(b) Remove the cap and strainer from the reservoir.
2. REMOVE 2 GROMMETS
3. PLACE CYLINDER IN VISE
4. 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)
5. 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 possi-
bility that the cylinder bore could be damaged.
At the time of reassembly, 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 piston drops out of the cylinder.
HINT:
Make sure the distance (A) from the rag to the top of the blocks
is at least 100 mm (3.94 in.).

BR02N−03
− BRAKEBRAKE MASTER CYLINDER
BR−13
1996 RAV4 (RM447U)
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.

BR02O−03
BR−14
− BRAKEBRAKE MASTER CYLINDER
1996 RAV4 (RM447U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page BR−12).
NOTICE:
Apply lithium soap base glycol grease to the rubber parts indicated by the arrows
(See page BR−9).

BR02P−03
− BRAKEBRAKE MASTER CYLINDER
BR−15
1996 RAV4 (RM447U)
INSTALLATION
Installation is in the reverse order of removal (See page BR−11).
1. BEFORE INSTALLATION, ADJUST LENGTH OF BRAKE BOOSTER PUSH ROD
(See page BR−19)
2. AFTER INSTALLATION, FILL BRAKE RESERVOIR WITH BRAKE FLUID, BLEED BRAKE SYS-
TEM (See page BR−4) AND CHECK FOR LEAKS
3. CHECK AND ADJUST BRAKE PEDAL (See page BR−6)
4. M/T:
AFTER INSTALLATION, BLEED CLUTCH SYSTEM

BR2237
BR02Q−02
BR2238
GOOD
1st2nd3rdNO GOOD BR−16
− BRAKEBRAKE BOOSTER ASSEMBLY
1996 RAV4 (RM447U)
BRAKE BOOSTER ASSEMBLY
ON−VEHICLE INSPECTION
1. OPERATING CHECK
(a) Depress the brake pedal several times with the engine
OFF and check that there is no change in the pedal re-
serve 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 farthest at the 1st time, but gradually
rises after at 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.

BR02R−08
− BRAKEBRAKE BOOSTER ASSEMBLY
BR−17
1996 RAV4 (RM447U)
COMPONENTS

BR02S−02
R10718
BR−18
− BRAKEBRAKE BOOSTER ASSEMBLY
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE MASTER CYLINDER (See page BR−9)
2. REMOVE CHARCOAL CANISTER
3. DISCONNECT VACUUM HOSE FROM BRAKE
BOOSTER
4. REMOVE PEDAL RETURN SPRING
5. REMOVE CLIP AND CLEVIS PIN
6. REMOVE BRAKE BOOSTER
(a) Remove the 4 nuts and clevis.
(b) Pull out the brake booster and gasket.

BR0M3−01
F03521
SST
Gasket
N00744
SST
− BRAKEBRAKE BOOSTER ASSEMBLY
BR−19
1996 RAV4 (RM447U)
INSTALLATION
1. INSTALL BRAKE BOOSTER
(a) Install the booster and a new gasket.
(b) Install the clevis to the operating rod.
(c) Install and torque the booster installation nuts.
Torque:
13 N·m (130 kgf·cm, 9 ft·lbf)
(d) Insert the clevis pin into clevis, brake pedal, and install the
clip to the clevis pin.
(e) Install the pedal return spring.
2. ADJUST LENGTH OF BOOSTER PUSH ROD
(a) Install a new gasket on the master cylinder.
(b) Set the SST on the gasket, and lower the pin until its tip
slightly touches the piston.
SST 09737−00010
(c) Turn the SST upside down, and set it on the booster.
SST 09737−00010
(d) Measure the clearance between the booster push rod
and pin head (SST).
Clearance: 0 mm (0 in.)
(e) Adjust the booster push rod length until the push rod
slightly touches the pin head.
3. INSTALL CHARCOAL CANISTER TO ORIGINAL POSI-
TION
4. INSTALL MASTER CYLINDER
5. CONNECT VACUUM HOSE TO BRAKE BOOSTER
6. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND
BLEED BRAKE SYSTEM (See page BR−4)
7. M/T:
BLEED CLUTCH SYSTEM
8. CHECK FOR LEAKS
9. CHECK AND ADJUST BRAKE PEDAL
(See page BR−6)
Check and adjust the brake pedal, then tighten the clevis lock
nut.
Torque:
25 N·m (260 kgf·cm, 19 ft·lbf)
10. DO OPERATIONAL CHECK (See page BR−16)

BR02Y−11
BR−20
− BRAKEFRONT BRAKE PAD
1996 RAV4 (RM447U)
FRONT BRAKE PAD
COMPONENTS

BR0M4−01
R10627
R10628
− BRAKEFRONT BRAKE PAD
BR−21
1996 RAV4 (RM447U)
REPLACEMENT
1. REMOVE FRONT WHEEL
Remove the wheel and temporarily fasten the disc with the hub
nuts.
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. LIFT UP CALIPER
(a) Remove the flexible hose from the shock absorber brack-
et.
(b) Hold the sliding pin on the bottom and loosen the installa-
tion bolt.
(c) Remove the installation bolt.
(d) Lift up the caliper and suspend it securely.
HINT:
Do not disconnect the flexible hose from the caliper.
4. REMOVE THESE PARTS:
2 brake pads
4 anti−squeal shims
4 pad support plates
NOTICE:
The support plates 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.
5. CHECK DISC THICKNESS AND RUNOUT
(See page BR−26)
6. INSTALL 4 PAD SUPPORT PLATES