brake pads TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine MA0055
MA014−01
− MAINTENANCEBRAKE
MA−7
42 Author: Date:
1996 TOYOTA T100 (RM449U)
BRAKE
INSPECTION
1. INSPECT BRAKE LINE PIPES AND HOSES
HINT:
Inspect in a well−lighted area. Inspect the entire circumference
and length of the brake hoses using a mirror as required. Turn
the front wheels fully right or left before inspecting the front
brake.
(a) Check all brake lines and hoses for:
Damage
Wear
Deformation
Cracks
Corrosion
Leaks
Bends
Twists
(b) Check all clamps for tightness and connections for leak-
age.
(c) Check that the hoses and lines are clear of sharp edges,
moving parts and the exhaust system.
(d) Check that the lines installed in grommets pass through
the center of the grommets.
2. INSPECT FRONT BRAKE PADS AND DISCS
(2WD: See page BR−22)
(4WD: See page BR−25)
HINT:
If a squealing or scraping noise occurs from the brake during
driving, check the pad wear indicator.
If there are traces of the indicator contacting the disc rotor, the
disc pad should be replaced.
3. INSPECT REAR BRAKE LININGS AND DRUMS
(2WD: See page BR−42)
(4WD: See page BR−48)

Downloaded from www.Manualslib.com manuals search engine BR094−01
BR3082
R04837
BR3312
BR−22
− BRAKEFRONT BRAKE PAD (2WD)
1996 TOYOTA T100 (RM449U)
REPLACEMENT
1. REMOVE FRONT WHEEL
Remove the wheel and temporarily fasten the disc with hub
nuts.
2. INSPECT PAD LINING THICKNESS
Check the pad thickness through the caliper inspection hole
and replace pads if not within specification.
Minimum thickness: 1.0 mm (0.039 in.)
3. LIFT UP CALIPER
(a) Remove the installation bolt.
(b) Lift up the caliper and suspend it securely.
HINT:
Do not disconnect the flexible hose from the caliper.
4. REMOVE THESE PARTS:
1 ton:
2 anti−squeal springs
2 brake pads
2 (1 ton) / 4 (0.5 ton) anti−squeal shims
2 pad wear indicator plates
4 pad support plates
NOTICE:
The anti−squeal springs (1 ton) and support plates can be
used again provided that they have sufficient rebound, no
deformation, cracks or wear, and have had all rust, dirt and
foreign particles cleaned off.
5. CHECK DISC THICKNESS AND RUNOUT
(See page BR−30)
6. INSTALL 4 PAD SUPPORT PLATES
7. INSTALL NEW PADS
NOTICE:
When replacing worn pads, the anti−squeal shims and
wear indicator plates must be replaced together with the
pads.
(a) Install a pad wear indicator plate to the pad.
(b) 1 ton:
Install the anti−squeal shim to each pad.
(c) 0.5 ton:
Install the 4 anti−squeal shims to each pad.
HINT:
Apply disc brake grease to both sides of inner anti−squeal
shims (See page BR−21).

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 BR096−01
R08165
Z04448
R08166
− BRAKEFRONT BRAKE PAD (4WD)
BR−25
1996 TOYOTA T100 (RM449U)
REPLACEMENT
1. REMOVE FRONT WHEEL
2. INSPECT PAD LINING THICKNESS
Check the pad thickness and replace pads if not within specifi-
cation.
Minimum thickness: 1.0 mm (0.039 in.)
3. REMOVE THESE PARTS:
Clip
2 pins
Anti−rattle spring
2 pads
4 anti−squeal shims
NOTICE:
The anti−rattle spring can be used again provided that they
have sufficient rebound, no deformation, cracks or wear,
and have had all rust, dirt and foreign particles cleaned off.
4. CHECK DISC THICKNESS AND RUNOUT
(See page BR−36)
5. INSTALL NEW PADS
NOTICE:
When replacing worn pads, the anti−squeal shims must be
replaced together with the pads.
(a) Draw out a small amount of brake fluid from the reservoir.
(b) Press in the pistons with a hammer handle or equivalent.
HINT:
Always change the pad on one wheel at a time as there
is a possibility of the opposite piston flying out.
If the piston is difficult to push in, loosen the bleeder plug
and push in the piston while letting some brake fluid es-
cape.
(c) Install the 4 anti−squeal shims to new pads.
HINT:
Apply disc brake grease to the inner anti−squeal shims (See
page BR−24).
(d) Install the 2 pads.
NOTICE:
Do not allow oil or grease on the rubbing face.
6. INSTALL ANTI−RATTLE SPRING AND 2 PINS
7. INSTALL CLIP

Downloaded from www.Manualslib.com manuals search engine BR098−03
R04699
− BRAKEFRONT BRAKE CALIPER (2WD)
BR−27
1996 TOYOTA T100 (RM449U)
REMOVAL
1. DISCONNECT FLEXIBLE HOSE
(a) Remove the union bolt and disconnect the flexible hose.
Torque: 15 N·m (155 kgf·cm, 11 ft·lbf)
NOTICE:
At the time of installation, please refer to the following item.
For correct brake hose routing, ensure that the hose hangs
down before installing hose to caliper.
(b) Use a container to catch the brake fluid.
2. REMOVE CALIPER FROM TORQUE PLATE
Remove the 2 installation bolts and caliper.
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)
3. REMOVE THESE PARTS:
1 ton:
2 anti−squeal springs
2 brake pads with anti−squeal shims
4 pads support plates

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