boot TOYOTA T100 1996 Factory Workshop Manual

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 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 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

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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 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 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.

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Turn Pressure Tube
Dust Cover
Control Valve Housing
 Gasket
Control Valve Assembly
Steering Rack Stopper Rack End
Tie Rod EndCylinder End Rack Housing Cap Rack GuideRack Housing
Rack Guide
Spring Oil Seal
 Bearing
 Teflon Ring
 Bearing  Oil Seal  Oil Seal O−Ring
 O−Ring
 Rack Guide Spring
 Rack GuideCap Lock Nut
Spring Cap Bearing
 Self−Locking Nut
Rack Bushing O−Ring  Oil Seal  Wire  Claw Wash
 O−Ring Clip
 Teflon Ring Lock Nut
Rack Boot
Clamp
Non−reusable part
Precoated part
Molybdenum disulfide lithium base grease Power steering fluid 

18 (185, 13)
13 (130, 9)
*10 (102, 7) 13 (130, 9)
*10 (102, 7)
: Specified torque
N·m (kgf·cm, ft·lbf)
*for use with SST56 (570, 41)
60 (700, 51)
*51 (521, 38)
25 (250, 18)
69 (700, 51)
83 (850, 62)
*61 (618, 45)
− STEERINGPOWER STEERING GEAR (2WD)
SR−55
1729 Author: Date:
1996 TOYOTA T100 (RM449U)

Downloaded from www.Manualslib.com manuals search engine SR07W−01
R15215
SST
R04580
SST
R00429
Matchmark
R12979
R04582
− STEERINGPOWER STEERING GEAR (2WD)
SR−57
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. REMOVE 2 TURN PRESSURE TUBES
(a) Remove the bolt and clamp plate.
(b) Using SST, remove the tube.
SST 09633−00020
(c) Remove the 2 O−rings from the tube.
2. SECURE PS GEAR ASSEMBLY IN VISE
Using SST, secure the gear assembly in a vise.
SST 09612−00012
3. REMOVE RH AND LH TIE ROD ENDS AND LOCK
NUTS
Place matchmarks on the tie rod end and rack end.
4. REMOVE RH AND LH CLIPS, RACK BOOTS AND
CLAMPS
Using a screwdriver, loosen the clamp.
NOTICE:
Be careful not to damage the boot.
Mark the RH and LH boots.
5. REMOVE RH AND LH RACK ENDS AND CLAW
WASHERS
(a) Using a chisel and a hammer, unstake the washer.
NOTICE:
Avoid any impact to the steering rack.

Downloaded from www.Manualslib.com manuals search engine SR07Y−01
F00854
SSTSST
Oil Seal
SST Vinyl Tape
W03126
Rack Teeth End
SST SR−64
− STEERINGPOWER STEERING GEAR (2WD)
1996 TOYOTA T100 (RM449U)
REASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. COAT WITH POWER STEERING FLUID OR MOLYBDE-
NUM DISULFIDE LITHIUM BASE GREASE (See page
SR−54)
2. INSTALL OIL SEAL
(a) Coat a new oil seal lip with power steering fluid.
(b) Using SST, press in the oil seal.
SST 09950−60010 (09951−00240, 09951−00430,
09952−06010), 09950−70010 (09951−07360)
NOTICE:
Make sure to install the oil seal facing the correct
direction.
Take care that the oil seal does not get reversed as
you install it.
3. INSTALL STEERING RACK
HINT:
If necessary, scrape the burrs off the rack teeth end then clean
and burnish before installation.
(a) Make sure that the tube hole is not clogged with grease.
HINT:
If the tube hole is clogged, the pressure inside the boot will
change after it is assembled and the steering wheel turned.
(b) Install SST to the rack.
SST 09631−33010
(c) Coat SST with power steering fluid.
(d) Insert the rack into the rack housing.
NOTICE:
Be careful not to damage the oil seal lip.
(e) Remove the SST.