TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine R09581
BR09U−02
BR1638
BR3338
BR0589
BR0070
Valve Side Shackle Side BR−54
− BRAKELOAD SENSING PROPORTIONING AND BY−PASS
VALVE (LSP & BV)
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. REMOVE VALVE BRACKET
(a) Remove the nut and bolt.
CAUTION:
At the time of reassembly, please refer to the following
item. When connecting the shackle to the load sensing with
a bolt and nut, insert the bolt from the front side of vehicle.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
(b) Remove the 2 nuts, and remove the bracket and set plate
from the valve body.
HINT:
At the time of reassembly, please refer to the following item.
Finger tighten the valve body mounting nuts.
2. DISCONNECT SPRING FROM VALVE
Using pliers, remove the clip and the spring from the valve.
3. REMOVE SHACKLES NO.1 AND NO.2
(a) Remove the nuts and bolts, and then remove No.1 and
No.2 shackles and 2 plate washers from the load sensing
spring assembly.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
(b) Loosen the 2 nuts, remove the nut and shackle No.1 from
the shackle No.2.
4. DISASSEMBLE LOAD SENSING SPRING
Disassemble these parts:
4 Bushings
2 Collars
2 Rubber plates
Load sensing valve boot
Load sensing spring boot
HINT:
At the time of reassembly, please refer to the following items.
Apply lithium soap−base glycol grease to all rubbing
areas.
Do not mistake the valve side for the shackle side of the
load sensing spring.

Downloaded from www.Manualslib.com manuals search engine BR09V−01
Z03645
Wear Limit 0.7 mm
− BRAKELOAD SENSING PROPORTIONING AND BY−PASS
VALVE (LSP & BV)BR−55
1996 TOYOTA T100 (RM449U)
INSPECTION
INSPECT VALVE PISTON PIN AND LOAD SENSING CON-
TACT SURFACE FOR WEAR
Wear limit: 0.7 mm (0.028 in.)

Downloaded from www.Manualslib.com manuals search engine BR09W−01
BR−56− BRAKELOAD SENSING PROPORTIONING AND BY−PASS
VALVE (LSP & BV)
1996 TOYOTA T100 (RM449U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page BR−54).

Downloaded from www.Manualslib.com manuals search engine BR09X−01
Z11332
SST
Z11333
A
BR0218
BR0061
SST
− BRAKELOAD SENSING PROPORTIONING AND BY−PASS
VALVE (LSP & BV)BR−57
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. INSTALL LSP & BV ASSEMBLY TO FRAME
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
2. CONNECT BRAKE LINE
Using SST, connect the brake lines.
Torque: 15 N·m (155 kgf·cm, 11 ft·lbf)
SST 09751−36011
3. CONNECT SHACKLE NO.2 BRACKET
(a) Install the shackle No.2 to the load sensing spring.
(b) Set dimension A and torque the lock nut.
Initial set: 120 mm (4.72 in.)
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(c) Connect the shackle No.2 to the shackle bracket.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
(d) Install a new cotter pin.
4. SET REAR AXLE LOAD
(See page BR−50)
5. SET VALVE BODY
(a) When pulling down the load sensing spring, check that
the valve piston moves down smoothly.
(b) Position the valve body so that the valve piston lightly
contacts with the load sensing spring.
(c) Tighten the valve body mounting nuts.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
6. BLEED BRAKE LINE (See page BR−4)
7. CHECK AND ADJUST LSP & BV FLUID PRESSURE
(See page BR−50)
8. APPLY SEALANT TO SHACKLE No.2
Apply sealant to the top portion of the shackle No.2 bolt threads
not to lose the upper lock nut.
Sealant:
Part No. 08833−00070, THREE BOND 1324 or equiva-
lent

Downloaded from www.Manualslib.com manuals search engine F14857
BR1NW−01
R07778
BR−58
− BRAKEABS ACTUATOR
1663 Author: Date:
1996 TOYOTA T100 (RM449U)
ABS ACTUATOR
ON−VEHICLE INSPECTION
1. INSPECT BATTERY POSITIVE VOLTAGE
Battery positive voltage: 10 − 14 V
2. DISCONNECT CONNECTORS
(a) Disconnect the 2 connectors from the control relay.
(b) Disconnect the connector from the actuator.
3. CONNECT ACTUATOR CHECKER (SST) TO ACTUA-
TOR
(a) Connect the actuator checker (SST) to the actuator, con-
trol relay and body side wire harness through the sub−
wire harness C and E (SST) as shown in the illustration.
SST 09990−00150, 09990−00200, 09990−00210
(b) Connect the red cable of the checker to the battery posi-
tive (+) terminal and black cable to the negative (−) termi-
nal. Connect the black cable of the sub−wire harnesses
to the battery negative (−) terminal or body ground.
(c) Place the ”SHEET L” (SST) on the actuator checker.
SST 09990−00370
4. INSPECT BRAKE ACTUATOR OPERATION
(a) Start the engine, and run it at idle.
(b) Turn the selector switch of the actuator checker in
”FRONT” position.
(c) Push and hold in the MOTOR switch for a few seconds.
Make sure that you can hear the motor running.

Downloaded from www.Manualslib.com manuals search engine R07779
R07780
R07781
R07782
− BRAKEABS ACTUATOR
BR−59
1664 Author: Date:
1996 TOYOTA T100 (RM449U)
(d) Depress the brake pedal and hold it until the step (g) is
completed.
(e) Push the POWER SWITCH, and check that the brake
pedal does not go down.
NOTICE:
Do not keep the POWER SWITCH pushed down for more
than 10 seconds.
(f) Release the switch, and check that the pedal goes down.
(g) Push and hold in the MOTOR switch for a few seconds,
and check that the pedal returns.
(h) Release the brake pedal.
(i) Push and hold in the MOTOR switch for a few seconds.
(j) Depress the brake pedal and hold it for about 15 seconds.
As you hold the pedal down, push the MOTOR switch for
a few seconds. Check that the brake pedal does not pul-
sate.
(k) Release the brake pedal.
5. INSPECT FOR OTHER WHEELS
(a) Change the connection of the actuator checker (SST) to
the sub − wire harness E (SST) − from the sub − wire har-
ness MAIN connector to the SUB connector, or vice ver-
sa.
(b) Repeating (c) to (i) of the step 4, check the actuator opera-
tion same way.
6. INSPECT FOR REAR WHEEL
(a) Turn the selector switch to the ”REAR” position.
(b) Push and hold in the MOTOR switch for a few seconds.
(c) Depress the brake pedal and hold it until the step (g) is
completed.

Downloaded from www.Manualslib.com manuals search engine R07783
R07784
R07785
R07782
BR−60
− BRAKEABS ACTUATOR
1665 Author: Date:
1996 TOYOTA T100 (RM449U)
(d) Push the REAR switch while pressing the POWER
SWITCH, and check that the brake pedal cannot be de-
pressed.
NOTICE:
Do not keep the POWER SWITCH pushed down for more
than 10 seconds.
(e) Release the REAR switch then the POWER SWITCH,
and check that the brake pedal can be depressed.
(f) Push and hold in the MOTOR switch for a few seconds,
and check that the pedal returns.
(g) Release the brake pedal.
(h) Push and hold in the MOTOR switch for a few seconds.
(i) Depress the brake pedal and hold it for about 15 seconds.
As you hold the pedal down, push the MOTOR switch for
a few seconds. Check that the brake pedal does not pul-
sate.
(j) Release the brake pedal.
7. PUSH MOTOR SWITCH
(a) Push and hold on the MOTOR switch for a few seconds.
(b) Stop the engine.
8. DISCONNECT ACTUATOR CHECKER (SST) FROM
ACTUATOR
Remove the ”SHEET L” (SST) and disconnect the actuator
checker (SST) and sub−wire harness (SST) from the actuator,
control relay and body side wire harness.
SST 09990−00150, 09990−00200, 09990−00210,
09990−00370
9. CONNECT CONNECTOR TO ACTUATOR
10. CLEAR DTC (See page DI−321)

Downloaded from www.Manualslib.com manuals search engine BR09Z−02
F14858
− BRAKEABS ACTUATOR
BR−61
1996 TOYOTA T100 (RM449U)
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine BR0A0−02
F14859
BR−62
− BRAKEABS ACTUATOR
1996 TOYOTA T100 (RM449U)
REMOVAL
1. DISCONNECT BRAKE LINES
Using SST, disconnect the 5 brake lines from the ABS actuator.
SST 09023−00100
Torque: 15 N·m (155 kgf·cm, 11 ft·lbf)
2. REMOVE ABS ACTUATOR ASSEMBLY
(a) Disconnect the 2 connectors from the actuator.
(b) Remove the 2 bolts, 2 nuts and ABS actuator assembly.
Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
3. REMOVE ABS ACTUATOR
(a) Remove the 3 nuts and ABS actuator from the actuator
bracket.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
(b) Remove the 3 holders and cushions from the ABS actua-
tor.

Downloaded from www.Manualslib.com manuals search engine BR0A1−01
− BRAKEABS ACTUATOR
BR−63
1996 TOYOTA T100 (RM449U)
INSTALLATION
Installation is in the reverse order of removal (See page BR−62).
1. AFTER INSTALLATION, FILL BRAKE RESERVOIR BRAKE FLUID AND BLEED BRAKE SYSTEM
(See page BR−4)
2. CHECK FOR LEAKS.