TOYOTA SUPRA 1995 Service Repair Manual

GENERAL DESCRIPTION
1. Care must be taken to replace each part properly as it could affect the performance of the brake
system and result in a driving hazard. Replace the parts with parts of the same part number or
equivalent.
2. It is very important to keep parts and the area clean when repairing the brake system.
3. If the vehicle is equipped with a mobile communication system, refer to the precaution in the IN
section. BR±2
± BRAKE SYSTEMGENERAL DESCRIPTION

PREPARATION
SST (SPECIAL SERVICE TOOLS)
09023±00100
09709±29017
09718±20010
09737±00010
09751±36011
09843±18020
09990±00150
09990±00163
09990±00200
09990±00210
09990±00250
09990±00280
09990±00330
Union Nut Wrench 10 mm
LSPV Gauge Set
Brake Shoe Return Spring
Replacer
Brake Booster Push Rod Gauge
Brake Line Union Nut 10 x 12 mm
Wrench
Diagnosis Check Wire
ABS Actuator Checker and
Sub±harness
ABS Actuator Checker Sheet ªAº
ABS Actuator Checker Sub±harness
ªCº
ABS Actuator Checker Sub±harness
ªEº
ABS Actuator Checker Sub±harness
ªGº
ABS Actuator Checker Sub±harness
ªHº
TRAC Actuator Air Bleed Wire
w/o TRAC
w/ TRAC
w/ TRAC
w/ TRAC
± BRAKE SYSTEMPREPARATIONBR±3

RECOMMENDED TOOLS
TOYOTA Electrical Tester Set
Snap Ring Pliers
09082±00050
09905±00013
EQUIPMENT
 
 Torque wrench 
 
 
 Micrometer 
 Brake disc
 
 Dial indicator 
 Brake disc
 
 Vernier calipers 
 Brake disc
LUBRICANT
 Item Capacity Classification 
 Brake fluid
 
 ±
 
 SAEJ1703 or FMVSS No.116, DOT 3
BR±4± BRAKE SYSTEMPREPARATION

BR±17,22,26,31BR±17,22,26,31BR±17,22,26,31BR±17,22,26,31BR±17,22,26,31BR±17,22,26,31BR±17,22,26,31BR±17,22,26,31BR±17,22,26,31BR±17,22,26,31BR±17,22,26,31BR±17,22,26,31BR±35BR±17,22,26,31BR±7BR±35BR±16BR±10BR±39BR±11BR±6
Low pedal or spongy pedal
Brake drag
Brake pull
Hard pedal but brake inefficient
Noise from brakes
See page
Part Name
Trouble
Brake system (fluid leaks)Brake pad (Worn)Brake system (Air in)Piston seal (Worn or damaged)Brake pedal (freeplay minimal)Master cylinder (Faulty)Parking brake wire (Sticking)Parking brake (Lever travel out of Adjustment)Parking brake (Shoe clearance out of adjustment)Piston (Frozen)Pad (Only)Piston (Stuck)Pad (Cracked or distorted)Tension or return spring (Faulty)Booster push rod (Out of adjustment)Sliding pin (Worn)Installation bolt (Loose)Pad support plate (Loose)Booster system (Vacuum leaks)Pad (Glazed)Pad (Dirty)Disc (Scored)Hold±down spring (Damaged)Anti±squeal shim (Damaged)
TROUBLESHOOTING
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.
± BRAKE SYSTEMTROUBLESHOOTINGBR±5

CHECK AND ADJUSTMENT
BRAKE PEDAL CHECK AND
ADJUSTMENT
1. CHECK THAT PEDAL HEIGHT IS CORRECT
Pedal height from dash panel:
154.2±164.2 mm (6.07±6.46 in.)
If the pedal height is incorrect, adjust it.
2. IF NECESSARY, ADJUST PEDAL HEIGHT
(a) Remove the lower instrument panel and finish panel.
(b) Disconnect the connector from the stop light switch.
(c) Loosen the stop light switch lock nut and remove the stop
light switch.
(d) Loosen the push rod lock nut.
(e) Adjust the pedal height by turning the pedal push rod.
(f) Tighten the push rod lock nut.
Torque: 25 NVm (260 kgfVcm, 19 ftVlbf)
(g) Install the stop light switch and turn it until it lightly contacts
the pedal stopper.
(h) Turn the stop light switch back one turn.
(i) Check the clearance (A) between stop light switch and pedal.
Clearance:
0.5±2.4 mm (0.02±0.09 in.)
(j) Tighten the stop light switch lock nut.
(k) Connect the connector to the stop light switch.
(l) Check that the stop lights come on when the brake pedal is
depressed, and go off when the brake pedal is released.
(m) After adjusting the pedal height, check the pedal free±play.
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.
(n) Install the lower instrument panel and finish panel.
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 beginning of the second
point of resistance is felt, then measure the distance, as
shown.
Pedal freeplay:
1±6 mm (0.04±0.24 in.)
If incorrect, check the stop light switch clearance. And if the
clearance is OK, then troubleshoot the brake system.
HINT: The freeplay to the 1st point of resistance is due to the
play between the clevis and pin. It is 1±3 mm (0.04±0.12 in.)
on the pedal. BR±6
± BRAKE SYSTEMCHECK AND ADJUSTMENT

4. CHECK PEDAL RESERVE DISTANCE
Release the parking brake.
With the engine running, depress the pedal and measure the
pedal reserve distance, as shown.
Pedal reserve distance at 490 N (50 kgf, 110.2 lbf):
w/o TRAC: More than 72 mm (2.83 in.)
w/ TRAC: More than 70 mm (2.76 in.)
If the reserve distance is incorrect, troubleshoot the brake
system.
BRAKE BOOSTER OPERATIONAL TEST
1. OPERATING CHECK
(a) Depress the brake pedal several times with the engine off
and check that there is no change in the pedal reserve
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 the 1st time, but gradually rises after 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.
BRAKE SYSTEM BLEEDING
HINT: If any work is done on the brake system or if air in the
brake lines is suspected, bleed the system of air.
NOTICE: Do not let brake fluid remain on painted sur-
faces. Wash it off immediately.
1. REMOVE RESERVOIR CAP
Turn the reservoir cap to the ºopenº side and remove it.
2. FILL RESERVOIR WITH BRAKE FLUID
Fluid:
SAE J1703 or FMVSS NO.116 DOT3
± BRAKE SYSTEMCHECK AND ADJUSTMENTBR±7

3. BLEED MASTER CYLINDER
HINT: If the master cylinder has been disassembled or if the
reservoir becomes empty, bleed the air from the master cylin-
der.
(a) Disconnect the brake lines from the master cylinder.
(b) Slowly depress the brake pedal and hold it.
(c) Block off the outer holes with your fingers, and release the
brake pedal.
(d) Repeat (b) and (c) 3 or 4 times.
4. BLEED BRAKE LINE
(a) Connect the vinyl tube to the brake caliper.
(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 air out of the brake
line for each wheel.
Torque: 11 NVm (110 kgfVcm, 8 ftVlbf)
5. CHECK FLUID LEVEL IN RESERVOIR
Check the fluid level and add fluid if necessary.
Fluid:
SAE J1703 or FMVSS NO.116 DOT3
6. INSTALL RESERVOIR CAP
(a) Align the matchmark on the reservoir cap with the matchmark
on the ºopenº side of reservoir.
(b) Push down on the reservoir cap and turn it clockwise until it
locks.
(c) Check that the matchmark on the reservoir cap is now
aligned with the matchmark on the ºcloseº side of the
reservoir. BR±8
± BRAKE SYSTEMCHECK AND ADJUSTMENT

TRAC CONTROL SYSTEM BLEEDING
HINT: When repairing the brake master cylinder or TRAC sys-
tem, bleed the air out of the TRAC system.
1. INSPECT BATTERY POSITIVE VOLTAGE
Battery positive voltage:
10±14 V
2. BLEED TRACTION CONTROL SYSTEM
(a) Disconnect the connector from the TRAC pump.
(b) Connect SST to the TRAC pump.
SST 09990±00330
(c) Connect a vinyl tube to the bleeder plug of the TRAC
actuator, then loosen the bleeder plug.
(d) Start the engine.
(e) Connect the SST to the battery. Then wait at least 60
seconds before tightening the bleeder plug with the TRAC
pump still operating.
Torque: 8.3 NVm (85 kgfVcm, 74 in.Vlbf)
(f) After tightening the bleeder plug, keep the TRAC pump
operating for approximately 30 seconds.
(g) Install the cap.
3. CHECK FLUID LEVEL IN RESERVOIR
Fluid:
SAE J1703 or FMVSS NO. 116 DOT3
4. CLEAR DIAGNOSTIC TROUBLE CODES
(See page BR±127)
± BRAKE SYSTEMCHECK AND ADJUSTMENTBR±9

PARKING BRAKE CHECK AND
ADJUSTMENT
1. CHECK PARKING BRAKE LEVER TRAVEL
Pull the parking brake lever all the way up, and count the
number of clicks.
Parking brake lever travel at 196 N (20 kgf, 44.1 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±39.
(a) Remove the upper console panel.
(b) Remove the screw and parking brake hole cover.
(c) Using a socket driver and spanner wrench, remove the
adjusting lock nut.
(d) Turn the adjusting nut until the lever travel is correct.
(e) Install the adjusting lock nut.
(f) Using a socket driver and spanner wrench, tighten the
adjusting lock nut.
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
(g) Install the parking brake hole cover with the screw.
(h) Install the upper console panel. BR±10
± BRAKE SYSTEMCHECK AND ADJUSTMENT

MASTER CYLINDER
MASTER CYLINDER REMOVAL
1. DISCONNECT LEVEL WARNING SWITCH CONNECTOR
2. DRAW OUT FLUID WITH SYRINGE
NOTICE: Do not let brake fluid remain on a painted sur-
face. Wash it off immediately.
3. DISCONNECT BRAKE LINES
Using SST, disconnect the brake lines from the master cylin-
der.
SST 09751±36011
± BRAKE SYSTEMMASTER CYLINDERBR±11