TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine BR09N−02
F01618
F01618
Bellcrank BootAdjuster
Parking Brake Bellcrank
No.1 or No.2Bleeder Plug
Wheel Cylinder
Parking Brake Cable No.2Rear Shoe Pin
Spring
 C−WasherClip
Spring Spring

−W asher
 C−Washer PistonBoot
Bellcrank
Bracket
Parking Brake Lever
Parking Brake Cable
No.1Dust Cover
Bellcrank No.3
Adjuster
Return
Spring
Anchor
Spring
Automatic Adjusting
Lever CupE−Ring Front Shoe
Gasket
Brake Drum Inspection
Hole plug
Pin
High temperature grease 
Non−reusable part
Lithium soap base glycol grease
N·m (kgf·cm, ft·lbf)Pin: Specified torque
Plug13 (130, 9)
Shoe Hold−Down Spring
Cup
11 (110, 8)
10 (100, 7)
15 (155, 11)
BR−44
− BRAKEREAR DRUM BRAKE (4WD)
1649 Author: Date:
1996 TOYOTA T100 (RM449U)
REAR DRUM BRAKE (4WD)
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine BR09O−01
BR1134
BR3116
BR0966
SST
BR0967
SST
BR0968
SST
− BRAKEREAR DRUM BRAKE (4WD)
BR−45
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 it is less than the minimum, replace the shoes.
Minimum thickness: 1.0 mm (0.03. 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 REAR 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 rear shoe and re-
move the rear shoe.
(d) Remove the anchor spring from the front shoe.
5. REMOVE FRONT SHOE
(a) Using SST, remove the shoe hold−down spring, cups and
pin.
SST 09718−00010
(b) Remove the return spring from the front shoe.
(c) Disconnect the parking brake cable No.1 from the parking
brake bellcrank No.3.
(d) Remove the front shoe with adjuster.
(e) Disconnect the parking brake cable from the front shoe.

Downloaded from www.Manualslib.com manuals search engine Z03633
Z03634
Z03635
BR3119
BR−46
− BRAKEREAR DRUM BRAKE (4WD)
1996 TOYOTA T100 (RM449U)
6. REMOVE ADJUSTER FROM FRONT SHOE
(a) Remove the adjusting lever spring.
(b) Remove the adjuster.
7. 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.
8. REMOVE AND DISASSEMBLE PARKING BRAKE
BELLCRANK
(a) Remove the clip and disconnect the parking brake cable.
(b) Remove the tension spring.
(c) Using a screwdriver, remove the bellcrank No.3 from the
backing plate with the parking brake cable No.2.
(d) Remove the parking brake bellcrank No.1 or No.2 and
dust cover with the 2 bolts.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
(e) Remove the bellcrank boot from the bellcrank bracket.
(f) Remove the C−washer and pin.
(g) Remove the parking brake bellcrank from the bellcrank
bracket.

Downloaded from www.Manualslib.com manuals search engine BR0970
SST
− BRAKEREAR DRUM BRAKE (4WD)
BR−47
1996 TOYOTA T100 (RM449U)
9. REMOVE WHEEL CYLINDER
(a) 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)
(b) Remove the 2 bolts and the wheel cylinder.
Torque: 10 N·m (100 kgf·cm, 7 ft·lbf)
10. 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 BR09P−01
R04717
BR0048
BR−48
− BRAKEREAR DRUM BRAKE (4WD)
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 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 BR09Q−01
BR0122
C
A
BAdjusting Bolt
BR0973
Z03640
Z03659
− BRAKEREAR DRUM BRAKE (4WD)
BR−49
1996 TOYOTA T100 (RM449U)
INSTALLATION
Installation is in the reverse order of removal (See page
BR−45).
NOTICE:
Apply lithium soap base glycol grease and high tempera-
ture grease to the parts indicated by the arrows (See page
BR−44).
1. ADJUST BELLCRANK
(a) Lightly pull the bellcrank in direction A until there is no
slack at part B.
(b) In this condition, turn the adjusting bolt so that dimension
C will be 0.4 − 0.8 mm (0.016 − 0.031 in.).
(c) Lock the adjusting bolt with the lock nut.
(d) Connect the parking brake cable to the parking brake bell-
crank and install the clip.
(e) Install the tension spring.
2. CHECK OPERATION OF AUTOMATIC ADJUSTING
MECHANISM
(a) Move the parking brake lever of the front shoe back and
forth. Check that the adjuster turns.
If the adjuster does not turn, check for incorrect installation of
the rear brakes.
(b) Adjust the adjuster length as short as possible.
(c) Install the brake drum.
(d) Pull the parking brake lever all the way up until a clicking
sound can no longer be heard.
3. CHECK CLEARANCE BETWEEN BRAKE SHOES AND
DRUM (See page BR−43)
Shoe clearance: 0.6 mm (0.024 in.)
4. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND
BLEED BRAKE SYSTEM (See Page BR−4)
5. CHECK FOR LEAKS

Downloaded from www.Manualslib.com manuals search engine BR0060
BR09R−11
BR0061
SST
BR0062
80 kg/cm2
BR−50− BRAKELOAD SENSING PROPORTIONING AND BY−PASS
VALVE (LSP & BV)
1655 Author: Date:
1996 TOYOTA T100 (RM449U)
LOAD SENSING PROPORTIONING
AND BY−PASS VALVE (LSP & BV)
ON−VEHICLE INSPECTION
1. SET REAR AXLE LOAD
Rear axle load (includes vehicle weight):
2WD:
1 ton: 850 kg (1,874 lb)
0.5 ton std: 800 kg (1,764 lb)
0.5 ton opt (soft ride): 850 kg (1,874 lb)
4WD: 1,050 kg (2,315 lb)
2. INSTALL LSPV GAUGE (SST) AND BLEED AIR
SST 09709−29017
3. RAISE FRONT BRAKE PRESSURE TO 7,845 kPa (80
kgf/cm
2, 1,138 psi) AND CHECK REAR BRAKE PRES-
SURE
Rear brake pressure:
5,325 ± 490 kPa (54.3 ± 5 kgf/cm
2, 772 ± 71 psi)
HINT:
The brake pedal should not be depressed twice and/or returned
while setting to the specified pressure. Read the value of rear
brake pressure after holding the specified fluid pressure for 2
seconds. If the brake pressure is incorrect, adjust the fluid pres-
sure.

Downloaded from www.Manualslib.com manuals search engine BR3278
R09580
Z11334
Z03643
− BRAKELOAD SENSING PROPORTIONING AND BY−PASS
VALVE (LSP & BV)BR−51
1656 Author: Date:
1996 TOYOTA T100 (RM449U)
4. IF NECESSARY, ADJUST FLUID PRESSURE
(a) Loosen the lock nut.
(b) Adjust the length of the No.2 shackle.
Low pressure: Lengthen A
High pressure: Shorten A
Initial set: 120 mm (4.72 in.)
Adjustment range: 114 − 126 mm (4.49 − 4.96 in.)
HINT:
One turn of the nut changes the fluid pressure as shown in the
following specification.
7.5 kPa (0.77 kgf/cm, 11 psi)
(c) Torque the lock nut.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(d) If the pressure cannot be adjusted by the No.2 shackle,
raise or lower the valve body. (2WD shown, for 4WD refer
to component illustration on next page.)
Low pressure−Lower body
High pressure−Raise body
(e) Torque the nuts.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
(f) Adjust the length of the No.2 shackle again.
If it cannot be adjusted, inspect the valve housing.
5. IF NECESSARY, CHECK VALVE BODY
(a) Assemble the valve body in the uppermost position.
HINT:
When the brakes are applied, the piston will move down about
0.8 mm (0.03 in.). Even at this time, the piston should not make
contact with or move the load sensing spring.
(b) In this position, check the rear brake pressure.
Front brake pressure
kPa (kgf/cm2, psi)
Rear brake pressure
kPa (kgf/cm2, psi)
1,960 (20, 285)1,960 (20, 285)
3,920 (40, 570)2,352 ± 196 (24 ± 2, 342 ± 28.5)
6,860 (70, 997.5)2,940 ± 343 (30 ± 3.5, 427.5 ± 50)
If the measured value is not within the standard, replace the
valve body.

Downloaded from www.Manualslib.com manuals search engine BR09S−08
R12821
R12821
Shackle Bracket Shackle No.2Load sensing Valve
4WD Only
Cotter Pin Load Sensing Spring AssemblyValve BracketN·m (kgf·cm,ft·lbf)
Collar
BushingSet Plate
2WD Only
Clip
Plate Washer
Shackle No.1 Plate Washer
Non−reusable part
Load Sensing Valve Boot
Rubber Plate
Collar
Load Sensing Spring BootBushing Bushing
BushingLoad Sensing
Spring
15 (155, 11)
18 (185, 13)
13 (130, 9)
: Specified torque
18 (185, 13)
13 (130, 9)
Retainer
25 (250, 18)
BR−52− BRAKELOAD SENSING PROPORTIONING AND BY−PASS
VALVE (LSP & BV)
1996 TOYOTA T100 (RM449U)
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine BR09T−01
R09582
Z11332
SST
− BRAKELOAD SENSING PROPORTIONING AND BY−PASS
VALVE (LSP & BV)BR−53
1996 TOYOTA T100 (RM449U)
REMOVAL
1. DISCONNECT SHACKLE NO.2 FROM BRACKET
(a) Remove the cotter pin.
(b) Remove the nut and cushion retainer, and disconnect the
shackle No.2.
(c) Remove the 2 bushings and collar.
2. REMOVE LSP & BV ASSEMBLY
(a) Using SST, disconnect the brake lines from the valve
body.
SST 09751−36011
(b) Remove the valve bracket mounting bolts and the LSP &
BV assembly.