TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine BR09E−01
R08172
SST
BR0961
BR−34
− BRAKEFRONT BRAKE CALIPER (4WD)
1996 TOYOTA T100 (RM449U)
REMOVAL
1. REMOVE FRONT WHEEL
2. DISCONNECT BRAKE LINE
Using SST, disconnect the brake line.
Use a container to catch the brake fluid.
SST 09751−36011
Torque: 15 N·m (155 kgf·cm, 11 ft·lbf)
3. REMOVE CALIPER
Remove the 2 mounting bolts and remove the caliper.
Torque: 123 N·m (1,250 kgf·cm, 90 ft·lbf)
4. REMOVE THESE PARTS:
Clip
2 pins
Anti−rattle spring
2 pads
4 anti−squeal shims

Downloaded from www.Manualslib.com manuals search engine BR09F−01
BR2008
BR0212
170 mm
(6.70 in.)50 mm
(1.97 in.)
16mm
(0.63 in.)
BR0213
BR2009
− BRAKEFRONT BRAKE CALIPER (4WD)
BR−35
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. REMOVE CYLINDER BOOT SET RINGS AND BOOTS
Using a screwdriver, remove the 4 cylinder boot set rings and
4 boots.
2. REMOVE PISTONS FROM CYLINDER
(a) Prepare the wooden plate to hold the pistons.
(b) Place the plate between the pistons and insert a pad at
one side.
(c) Use compressed air to remove the pistons alternately
from the cylinder.
CAUTION:
Do not place your fingers in front of the pistons when using
compressed air.
3. REMOVE PISTON SEALS
Using a screwdriver, remove the 4 seals from the cylinder.

Downloaded from www.Manualslib.com manuals search engine BR09G−01
BR0251
BR3183
R08168
BR−36
− BRAKEFRONT BRAKE CALIPER (4WD)
1996 TOYOTA T100 (RM449U)
INSPECTION
1. MEASURE PAD LINING THICKNESS
Using a ruler, measure the pad lining thickness.
Standard thickness: 9.5 mm (0.374 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 front axle hub (See page SA−23).
(b) Install the new axle hub with disc and adjust the front
bearing preload (See page SA−25).

Downloaded from www.Manualslib.com manuals search engine BR09H−01
− BRAKEFRONT BRAKE CALIPER (4WD)
BR−37
1996 TOYOTA T100 (RM449U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page BR−35).
NOTICE:
Apply lithium soap base glycol grease to the parts indicated by the arrows (See page BR−33).

Downloaded from www.Manualslib.com manuals search engine BR09I−01
BR−38
− BRAKEFRONT BRAKE CALIPER (4WD)
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 BR09J−02
F00995
F00995
Adjuster
Wheel Cylinder
Parking Brake Lever
Shoe Hold−Down Spring
Adjusting Lever
Front Shoe
Brake DrumBoot
Piston Boot
Piston
 C−Washer
Cup
 E−Ring
CupAdjusting
Lever SpringSpring
Gasket Anchor Spring
Shoe Hold−Down SpringReturn SpringAdjuster
Pin

Lithium soap base glycol grease
High temperature grease Non−reusable part
N·m (kgf·cm, ft·lbf)Bleeder Plug: Specified torque
15 (155, 11)
10 (100, 7)
11 (110, 8)
Cup
Cup
− BRAKEREAR DRUM BRAKE (2WD)
BR−39
1644 Author: Date:
1996 TOYOTA T100 (RM449U)
REAR DRUM BRAKE (2WD)
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine BR09K−01
R08164
BR3096
R04711
SST
R04712
SST
R04713
SST BR−40
− BRAKEREAR DRUM BRAKE (2WD)
1996 TOYOTA T100 (RM449U)
REMOVAL
1. INSPECT SHOE LINING THICKNESS
Remove the inspection hole plug, and check the shoe lining
thickness through the hole.
If less than minimum, replace the shoes.
Minimum thickness: 1.0 mm (0.039 in.)
2. REMOVE REAR WHEEL
3. REMOVE BRAKE DRUM
HINT:
If the brake drum cannot be removed easily, do the following
steps.
(a) Remove the adjusting hole plug in the backing plate.
(b) Insert a screwdriver through the hole in the backing plate,
and hold the automatic adjusting lever away from the ad-
justing bolt.
(c) Using another screwdriver, reduce the brake shoe adjust-
ment by turning the adjusting bolt.
4. REMOVE FRONT SHOE
(a) Using SST, disconnect the return spring.
SST 09703−30010
(b) Using SST, remove the shoe hold−down spring, cups and
pin.
SST 09718−00010
(c) Disconnect the anchor spring from the front shoe and re-
move the front shoe.
(d) Remove the anchor spring from the rear shoe.
5. REMOVE ADJUSTER AND REAR SHOE
(a) Using SST, remove the shoe hold−down spring, cups and
pin.
SST 09718−00010
(b) Remove the adjusting lever spring.

Downloaded from www.Manualslib.com manuals search engine R04715
Z03621
BR3027
SST
− BRAKEREAR DRUM BRAKE (2WD)
BR−41
1996 TOYOTA T100 (RM449U)
(c) Remove the adjuster with the return spring together.
(d) Using pliers, disconnect the parking brake cable from the
lever and remove the rear shoe.
6. REMOVE AUTOMATIC ADJUSTING LEVER AND
PARKING BRAKE LEVER
(a) Remove the E−ring.
(b) Remove the automatic adjusting lever.
(c) Remove the C−washer.
(d) Remove the parking brake lever.
7. REMOVE WHEEL CYLINDER
(a) Using SST, disconnect the brake line from the cylinder.
Use a container to catch the brake fluid.
SST 09751−36011
Torque: 15 N·m (155 kgf·cm, 11 ft·lbf)
(b) Remove the 2 bolts and wheel cylinder.
Torque: 10 N·m (100 kgf·cm, 7 ft·lbf)
8. DISASSEMBLE WHEEL CYLINDER
Remove these parts from the wheel cylinder.
2 boots
2 pistons
2 piston cups
Spring

Downloaded from www.Manualslib.com manuals search engine BR09L−01
BR0047
R04717
BR0048
BR−42
− BRAKEREAR DRUM BRAKE (2WD)
1996 TOYOTA T100 (RM449U)
INSPECTION
1. INSPECT DISASSEMBLED PARTS
Inspect the disassembled parts for wear, rust or damage.
2. MEASURE BRAKE SHOE LINING THICKNESS
Using a ruler, measure the shoe lining thickness.
Standard thickness: 6.0 mm (0.236 in.)
Minimum thickness: 1.0 mm (0.039 in.)
If the shoe lining is less than the minimum or shows signs of un-
even wear, replace the brake shoes.
HINT:
If any of the brake shoes have to be replaced, replace all of the
rear brake shoes in order to maintain even braking.
3. MEASURE BRAKE DRUM INSIDE DIAMETER
Using a vernier calipers, measure the inside diameter of drum.
Standard inside diameter: 295.0 mm (11.614 in.)
Maximum inside diameter: 297.0 mm (11.693 in.)
If the drum is scored or worn, the brake drum may be lathed to
the maximum inside diameter.
4. INSPECT BRAKE LINING AND DRUM FOR PROPER
CONTACT
If the contact between the brake lining and drum is improper, re-
pair the lining with a brake shoe grinder, or replace the brake
shoe assembly.

Downloaded from www.Manualslib.com manuals search engine BR09M−01
R04724
BR0080
R04725
− BRAKEREAR DRUM BRAKE (2WD)
BR−43
1996 TOYOTA T100 (RM449U)
INSTALLATION
Installation is in the reverse order of removal (See page
BR−40).
NOTICE:
Apply lithium soap base glycol grease and high tempera-
ture grease to the parts indicated by the arrows (See page
BR−39).
1. CHECK OPERATION OF AUTOMATIC ADJUSTER
MECHANISM
(a) Move the parking brake lever of the rear shoe back and
forth, as shown. Check that the adjusting bolt turns.
If the adjuster does not turn, check for incorrect installation of
the rear brakes.
(b) Adjust the adjuster length to the shortest possible
amount.
(c) Install the drum.
(d) Pull the parking brake lever all the way up until a clicking
sound can no longer be heard.
2. CHECK CLEARANCE BETWEEN BRAKE SHOES AND
DRUM
(a) Remove the drum.
(b) Measure the brake drum inside diameter.
(c) Measure the distance between brake shoes. Check that
the difference between the diameters is the correct shoe
clearance.
Shoe clearance: 0.6 mm (0.024 in.)
If incorrect, check the parking brake system.
3. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND
BLEED BRAKE SYSTEM (See Page BR−4)
4. CHECK FOR LEAKS