TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine BR095−02
Z18922Disc brake greaseInner
Anti−Squeal Shim
Outer Pad
Anti−Squeal Shim Inner Anti−Squeal Shim Anti−Squeal
Shim
Inner PadAnti−Squeal Spring
Pin Clip
Brake Caliper
Piston Seal
Piston Boot Set Ring DiscPiston Seal
Piston
Boot
Set Ring
Lithium soap base glycol grease
Pad Wear
Indicator Plate BR−24
− BRAKEFRONT BRAKE PAD (4WD)
1629 Author: Date:
1996 TOYOTA T100 (RM449U)
FRONT BRAKE PAD (4WD)
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine BR096−01
R08165
Z04448
R08166
− BRAKEFRONT BRAKE PAD (4WD)
BR−25
1996 TOYOTA T100 (RM449U)
REPLACEMENT
1. REMOVE FRONT WHEEL
2. INSPECT PAD LINING THICKNESS
Check the pad thickness and replace pads if not within specifi-
cation.
Minimum thickness: 1.0 mm (0.039 in.)
3. REMOVE THESE PARTS:
Clip
2 pins
Anti−rattle spring
2 pads
4 anti−squeal shims
NOTICE:
The anti−rattle spring 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.
4. CHECK DISC THICKNESS AND RUNOUT
(See page BR−36)
5. INSTALL NEW PADS
NOTICE:
When replacing worn pads, the anti−squeal shims must be
replaced together with the pads.
(a) Draw out a small amount of brake fluid from the reservoir.
(b) Press in the pistons with a hammer handle or equivalent.
HINT:
Always change the pad on one wheel at a time as there
is a possibility of the opposite piston flying 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 4 anti−squeal shims to new pads.
HINT:
Apply disc brake grease to the inner anti−squeal shims (See
page BR−24).
(d) Install the 2 pads.
NOTICE:
Do not allow oil or grease on the rubbing face.
6. INSTALL ANTI−RATTLE SPRING AND 2 PINS
7. INSTALL CLIP

Downloaded from www.Manualslib.com manuals search engine BR097−03
Z18924
Z18924
Gasket
Piston
Pad Piston Seal
Torque PlateBleeder Plug
Dust Boot
Sliding Bushing
Brake Caliper
Anti−Squeal Spring
Pad Wear Indicator Plate 1 ton :
0.5 ton :Dust Boot
Dust Boot Anti−Squeal Shim
Bleeder PlugBrake Caliper
Piston Seal
Piston
Torque Plate
Pad
Anti−Squeal Shim Pad Support Plate Boot
Set Ring
Boot
Pad Support PlateGasket
Sliding Pin
Inner Anti Squeal Shim
Pad Wear
Indicator Plate
Non−reusable part
Lithium soap base glycol grease
Disc brake grease

N·m (kgf·cm, ft·lbf)
: Specified torque
39 (400, 29)
36 (370, 27)
15 (155, 11)
15 (155, 11)
BR−26
− BRAKEFRONT BRAKE CALIPER (2WD)
1631 Author: Date:
1996 TOYOTA T100 (RM449U)
FRONT BRAKE CALIPER (2WD)
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine BR098−03
R04699
− BRAKEFRONT BRAKE CALIPER (2WD)
BR−27
1996 TOYOTA T100 (RM449U)
REMOVAL
1. DISCONNECT FLEXIBLE HOSE
(a) Remove the union bolt and disconnect the flexible hose.
Torque: 15 N·m (155 kgf·cm, 11 ft·lbf)
NOTICE:
At the time of installation, please refer to the following item.
For correct brake hose routing, ensure that the hose hangs
down before installing hose to caliper.
(b) Use a container to catch the brake fluid.
2. REMOVE CALIPER FROM TORQUE PLATE
Remove the 2 installation bolts and caliper.
Torque:
1 ton: 39 N·m (400 kgf·cm, 29 ft·lbf)
Torque:
0.5 ton: 36 N·m (370 kgf·cm, 27 ft·lbf)
3. REMOVE THESE PARTS:
1 ton:
2 anti−squeal springs
2 brake pads with anti−squeal shims
4 pads support plates

Downloaded from www.Manualslib.com manuals search engine BR099−02
BR3384
BR3079
BR0168
BR3080
BR−28
− BRAKEFRONT BRAKE CALIPER (2WD)
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. 1 ton:
REMOVE CALIPER SLIDING BUSHINGS AND DUST
BOOTS
(a) Remove the sliding bushings.
HINT:
At the time of reassembly, please refer to the following item.
Ensure that the boots are secured firmly to the caliper grooves.
(b) Using a screwdriver and a hammer, remove the dust
boots.
HINT:
At the time of reassembly, please refer to the following item.
Use 2 socket wrenches and a vise, press in new dust boots.
2. REMOVE CYLINDER BOOT SET RING (1 ton) AND
CYLINDER BOOT
Using a screwdriver, remove the cylinder boot set ring (1 ton)
and cylinder boot.
3. REMOVE PISTON FROM CYLINDER
(a) Put a piece of cloth or an equivalent between the piston
and caliper.
(b) Use compressed air to remove the piston from the cylin-
der.
CAUTION:
Do not place your fingers in front of the piston when using
compressed air.
4. REMOVE PISTON SEAL FROM BRAKE CYLINDER
Using a screwdriver, remove the piston seal.

Downloaded from www.Manualslib.com manuals search engine − BRAKEFRONT BRAKE CALIPER (2WD)
BR−29
1996 TOYOTA T100 (RM449U)
5. 0.5 ton:
REMOVE SLIDING PINS AND DUST BOOTS
(a) Remove the 2 sliding pins from the torque plate.
(b) Using a screwdriver and hammer, tap out the 2 dust
boots.
HINT:
At the time of reassembly, please refer to the following item.
Using a 19 mm socket and hammer, tap in 2 new dust boots into
the torque plate.
NOTICE:
At the time of reassembly, please refer to the following
item.
Confirm that the metal plate portion of the dust boot fits
snugly in the torque plate.

Downloaded from www.Manualslib.com manuals search engine BR09A−01
BR0251
R04701
R04702
BR0173
BR−30
− BRAKEFRONT BRAKE CALIPER (2WD)
1996 TOYOTA T100 (RM449U)
INSPECTION
1. MEASURE PAD LINING THICKNESS
Using a ruler, measure the pad lining thickness.
Standard thickness:
1 ton: 9.5 mm (0.374 in.)
Standard thickness:
0.5 ton: 11.0 mm (0.433 in.)
Minimum thickness:
1.0 mm (0.039 in.)
Replace the pad if the thickness is less than the minimum (the
1.0 mm slit is no longer visible), or if it shows signs of uneven
wear.
2. MEASURE DISC THICKNESS
Using a micrometer, measure the disc thickness.
Standard thickness: 25.0 mm (0.984 in.)
Minimum thickness: 23.0 mm (0.906 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 10 mm (0.39 in.)
from the outside edge of the disc.
Maximum disc runout: 0.07 mm (0.0028 in.)
If the runout is greater than the maximum, replace the disc or
grind it on a ”On−Car” brake lathe.
HINT:
Before measuring the runout, check that the front hub bearing
play is within specification.
4. IF NECESSARY, REPLACE DISC
(a) Remove the torque plate from the knuckle.
(b) Remove the axle hub (See page SA−16).
(c) Remove the disc from the axle hub.
(d) Install a new disc. Torque the bolts.
Torque: 64 N·m (650 kgf·cm, 47 ft·lbf)
(e) Install the axle hub and adjust the front bearing preload
(See page SA−19).
(f) Install the torque plate onto the knuckle.
Torque: 108 N·m (1,100 kgf·cm, 80 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine BR09B−01
− BRAKEFRONT BRAKE CALIPER (2WD)
BR−31
1996 TOYOTA T100 (RM449U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page BR−28).
NOTICE:
Apply lithium soap base glycol grease to the parts indicated by the arrows (See page BR−26).

Downloaded from www.Manualslib.com manuals search engine BR09C−01
BR−32
− BRAKEFRONT BRAKE CALIPER (2WD)
1996 TOYOTA T100 (RM449U)
INSTALLATION
Installation is in the reverse order of removal (See page BR−34).
1. AFTER INSTALLATION, FILL BRAKE RESERVOIR BRAKE FLUID AND BLEED BRAKE SYSTEM
(See page BR−4)
2. CHECK FOR LEAKS.

Downloaded from www.Manualslib.com manuals search engine BR09D−02
Z18922Z18922
Inner
Boot Disc
Piston
Set RingPin
Piston Seal Indicator Plate
Anti−Squeal Shim Inner Anti−Squeal Shim Anti−Rattle Spring
Anti−Squeal Shim
Clip
Set Ring Boot
Piston Piston SealAnti−Squeal
ShimBrake Caliper
Inner Pad
Outer Pad
Pad Wear
Lithium soap base glycol grease
Disc brake grease
N·m (kgf·cm, ft·lbf)
15 (155, 11)
123 (1,250, 90)
: Specified torque
− BRAKEFRONT BRAKE CALIPER (4WD)
BR−33
1638 Author: Date:
1996 TOYOTA T100 (RM449U)
FRONT BRAKE CALIPER (4WD)
COMPONENTS