boot TOYOTA T100 1996 Factory Owner's Guide

Downloaded from www.Manualslib.com manuals search engine R14642
Cap
Boot Strainer
Reservoir
No.1 Piston and Spring Reservoir Set Screw
Grommet
Snap Ring
Piston Stopper Bolt Gasket w/o ABS:
w/ ABS:
Cap
Strainer
Reservoir
GrommetGrommetNo.1 Piston and Spring
Boot
Snap Ring No.2 Piston and Spring
No.2 Piston and Spring
Piston Stopper Bolt Gasket Cylinder Body Cylinder Body
Reservoir Set Screw
Grommet
Lithium soap base glycol greaseNon−reusable part N·m (kgf·cm, ft·lbf) : Specified torque
1.7 (17.5, 15.2 in.·lbf)
10 (100, 7)
1.7 (17.5, 15.2 in.·lbf)
10 (100, 7)
BR−10
− BRAKEBRAKE MASTER CYLINDER
1615 Author: Date:
1996 TOYOTA T100 (RM449U)

Downloaded from www.Manualslib.com manuals search engine BR08V−02
BR2248
R12218
Soft Jaws
R12217
Soft Jaws BR−12
− BRAKEBRAKE MASTER CYLINDER
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. REMOVE MASTER CYLINDER BOOT
Using a screwdriver, remove the master cylinder boot.
NOTICE:
At the time of reassembly, please refer to the following
item.
Facing the UP mark on the master cylinder boot upwards,
install the cylinder boot to the master cylinder.
2. REMOVE RESERVOIR
(a) Remove the set screw and pull out the reservoir.
Torque: 1.7 N·m (17.5 kgf·cm, 15.2 in.·lbf)
(b) Remove the cap and strainer from the reservoir.
3. REMOVE 2 GROMMETS
4. PLACE CYLINDER IN VISE
5. REMOVE PISTON STOPPER BOLT
Using a screwdriver, push the pistons in all the way and remove
the piston stopper bolt and gasket.
HINT:
Tape the screwdriver tip before use.
Torque: 10 N·m (100 kgf·cm, 7 ft·lbf)
6. REMOVE 2 PISTONS AND SPRINGS
(a) Push in the piston with a screwdriver and remove the
snap ring with snap ring pliers.
HINT:
Tape the screwdriver tip before use.
(b) Remove the No.1 piston and spring by hand, pulling
straight out, not at an angle.
NOTICE:
If pulled out and installed at an angle, there is a possibility
that the cylinder bore could be damaged.
NOTICE:
At the time of reassembly, please refer to the following
item. Be careful not to damage the rubber lips on the pis-
tons.

Downloaded from www.Manualslib.com manuals search engine BR093−03
Z18924
PadAnti−Squeal Spring
Pad Wear Indicator Plate 1 ton :
Anti−Squeal Shim Pad Support PlateInner Anti Squeal Shim
Disc brake grease
Pad Pad Support Plate
Pad Wear
Indicator Plate 0.5 ton :Bleeder Plug
Dust Boot
Sliding Bushing
Brake Caliper
Dust Boot
Set Ring Torque PlatePiston
Piston Seal
BootGasket

Anti−Squeal Shim

Gasket

Brake Caliper
Piston Seal
Piston
Boot
Dust Boot  Bleeder Plug
Torque PlateSliding Pin
Lithium soap base glycol grease
Non−reusable part 
39 (400, 29)
36 (370, 27)
N·m (kgf·cm, ft·lbf)
: Specified torque
− BRAKEFRONT BRAKE PAD (2WD)
BR−21
1626 Author: Date:
1996 TOYOTA T100 (RM449U)
FRONT BRAKE PAD (2WD)
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine R05057
R05256
− BRAKEFRONT BRAKE PAD (2WD)
BR−23
1996 TOYOTA T100 (RM449U)
(d) Install the 2 pads so that the wear indicator plate is facing
underneath.
NOTICE:
Do not allow oil or grease on the rubbing face.
8. INSTALL CALIPER
(a) Draw out a small amount of brake fluid from the reservoir.
(b) Press in piston with a hammer handle or equivalent.
HINT:
If the piston is difficult to push in, loosen the bleeder plug and
push in the piston while letting some brake fluid escape.
(c) Insert the brake caliper carefully so the boot is not
wedged.
(d) Install and torque the installation bolts.
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)
9. INSTALL FRONT WHEEL
10. CHECK THAT FLUID LEVEL IS AT MAX LINE

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 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 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 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

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.