brake rotor 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 R05597
0.13 sec. 0.13 sec.
Braking
− DIAGNOSTICSANTI−LOCK BRAKE SYSTEM
DI−325
1996 TOYOTA T100 (RM449U)
(5) Drive the vehicle straight ahead at about 20 km/h
(12.4 mph) or more, and depress the brake pedal
strongly.
(6) Check that the warning light pattern changes while
braking, as shown.
If the operation is not as specified, inspect the deceleration sen-
sor installation. If the sensor installation is OK, replace the de-
celeration sensor.
(7) Stop the vehicle and turn the ignition switch OFF.
(8) Remove the SST from the terminals of the DLC1.
SST 09843−18020
(d) Check the DTC of the speed sensor function.
Code No.DiagnosisTrouble Area
71Low output voltage of right front speed sensorRight front speed sensor
Sensor installation
72Low output voltage of left front speed sensorLeft front speed sensor
Sensor installation
73Low output voltage of right rear speed sensorRight rear speed sensor
Sensor installation
74Low output voltage of left rear speed sensorLeft rear speed sensor
Sensor installation
75Abnormal change in output voltage of right front speed
sensorRight front speed sensor rotor
76Abnormal change in output voltage of left front speed
sensorLeft front speed sensor rotor
77Abnormal change in output voltage of right rear speed
sensorRight rear speed sensor rotor
78Abnormal change in output voltage of left rear speed
sensorLeft rear speed sensor rotor
79*Deceleration sensor is faultyDeceleration sensor
Sensor installation
*: 4WD models

Downloaded from www.Manualslib.com manuals search engine DI0ZQ−03
DI−326
− DIAGNOSTICSANTI−LOCK BRAKE SYSTEM
1996 TOYOTA T100 (RM449U)
DIAGNOSTIC TROUBLE CODE CHART
HINT:
Using SST 09843−18020, connect terminals Tc and E
1, and remove the short pin.
If a malfunction code is displayed during the DTC check, check the circuit listed that the code. For details
of each code, turn to the page referred to under the ”See Page” for respective ”DTC No.” in the DTC chart.
DTC No.
(See Page)Detection ItemTrouble Area
11
(DI−332)Open circuit in ABS control (solenoid) relay circuit
ABS control (solenoid) relay
Open or short in ABS control (solenoid) relay circuit
ECU
12
(DI−332)Short circuit in ABS control (solenoid) relay circuit
ABS control (solenoid) relay
B+ short in ABS control (solenoid) relay circuit
ECU
13
(DI−335)Open circuit in ABS control (motor) relay circuit
ABS control (motor) relay
Open or short in ABS control (motor) relay circuit
ECU
14
(DI−335)Short circuit in ABS control (motor) relay circuit
ABS control (motor) relay
B+ short in ABS control (motor) relay circuit
ECU
21
(DI−338)Open or short circuit in 2−position solenoid circuit for right front
wheelABS actuator
Open or short in SFRR or SFRH circuit
ECU
22
(DI−338)Open or short circuit in 2−position solenoid circuit for left front
wheelABS actuator
Open or short in SFLR or SFLH circuit
ECU
23
(DI−338)Open or short circuit in 2−position solenoid circuit for rear
wheelABS actuator
Open or short in SRR or SRH circuit
ECU
31
(DI−341)Right front wheel speed sensor signal malfunction
Right front, left front, right rear and left rear speed sensor
Open or short in each speed sensor circuit
ECU
32
(DI−341)Left front wheel speed sensor signal malfunction
33
(DI−341)Right rear wheel speed sensor signal malfunction
34
(DI−341)Left rear wheel speed sensor signal malfunction
35
(DI−341)Open circuit in left front or right rear wheel speed sensor.
36
(DI−341)Open circuit in right front or left rear wheel speed sensor.
37
(DI−345)Neither front speed sensor rotor missing
Front axle hub
Right front, left front speed sensor
Wire harness for sensor system
ECU
37
(DI−346)Some tire is different size from the other tiresTire size
ECU
41
(DI−347)Low battery positive voltage or abnormally high battery
positive voltage
Battery
IC regulator
Open or short in power source circuit
ECU

Downloaded from www.Manualslib.com manuals search engine BR3583
BR3582F00010
RotorSpeed Sensor
Magnet
To ECU
+V
−VHigh Speed
Low Speed
CoilNS
− DIAGNOSTICSANTI−LOCK BRAKE SYSTEM
DI−341
1996 TOYOTA T100 (RM449U)
DTC 31 − 36 Speed Sensor Circuit
CIRCUIT DESCRIPTION
The speed sensor detects wheel speed and sends the ap-
propriate signals to the ECU. These signals are used to control
the ABS system. The front and rear rotors each have 48 serra-
tions.
When the rotors rotate, the magnetic field emitted by the perma-
nent magnet in the speed sensor generates an AC voltage.
Since the frequency of this AC voltage changes in direct propor-
tion to the speed of the rotor, the frequency is used by the ECU
to detect the speed of each wheel.

DTC No.DTC Detecting ConditionTrouble Area
31, 32, 33, 34
Detection of any of conditions 1 through 3:
1. At vehicle speed of 10 km/h (6 mph) or more, pulses are
not input for 15 sec.
2. Momentary interruption of speed sensor signal occurs at
least 7 times in time between switching the ignition
switch ON and switching it OFF.
3. Abnormal fluctuation of speed sensor signals with ve-
hicle speed 20 km/h (12 mph) or more.
4. An open is detected in speed sensor circuit for 0.6 sec.
Right front, left front, right rear, left rear speed sensor
Open or short in each speed sensor circuit
ECU
35
Speed sensor signal is not input for about 1 sec. while left
front and right rear speed sensor signals are being
checked with IG switch ON.Open in left front or right rear speed sensor circuit
ECU
36
Speed sensor signal is not input for about 1 sec. while right
front and left rear speed sensor signals are being checked
with IG switch ON.Open in right front or left rear speed sensor circuit
ECU
HINT:
DTC No. 31 is for the right front speed sensor.
DTC No. 32 is for the left front speed sensor.
DTC No. 33 is for the right rear speed sensor.
DTC No. 34 is for the left rear speed sensor.
Fail safe function:
If trouble occurs in the speed sensor circuit, the ECU cuts off current to the ABS control (solenoid) relay and
prohibits ABS control.
DI10D−02

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R07772
BR3795
OK
NG
DI−344
− DIAGNOSTICSANTI−LOCK BRAKE SYSTEM
1996 TOYOTA T100 (RM449U)
3 Check sensor rotor and sensor installation.
Front
PREPARATION:
Remove the axle hub (See page SA−16 or SA−23).
CHECK:
Check the sensor rotor serrations.
OK:
No scratches or missing teeth.
CHECK:
Check the sensor tip.
OK:
No scratches or foreign objects on the sensor tip.
Rear
PREPARATION:
Remove the axle shaft (See page SA−131).
CHECK:
Check the sensor rotor serrations.
OK:
No scratches or missing teeth.
CHECK:
Check the sensor tip.
OK:
No scratches or foreign objects on the sensor tip.
CHECK:
Check the speed sensor installation.
OK:
The installation bolt is tightened properly and there is
no clearance between the sensor and steering
knuckle or rear axle carrier.
NG Replace speed sensor or rotor.
NOTICE:
Check the speed sensor signal last (See page DI−321).
OK
Check and repalce ABS ECU.

Downloaded from www.Manualslib.com manuals search engine − DIAGNOSTICSANTI−LOCK BRAKE SYSTEM
DI−345
1996 TOYOTA T100 (RM449U)
DTC 37 Neither Front Speed Sensor Rotor Missing
CIRCUIT DESCRIPTION
DTC No.DTC Detecting ConditionTrouble Area
37
With front wheels stationary and rear wheels rotating at
20+ km/h (12+ mph) for 10+ secs, turn ignition switch ON
then OFF 8 times, in succession.Front axle hub
Right front, left front speed sensor
Wire harness for sensor system
ECU
INSPECTION PROCEDURE
1 Check front axle hub (See page SA−15 or SA−22).
NG Replace front axle hub.
OK
2 Check front speed sensor (See page DI−341).
NG Replace front speed sensor.
OK
3 Check for open or short in harness and connector between speed sensor and
ECU (See page IN−26).
NG Repair or replace harness or connector.
OK
Check and replace ABS ECU.
DI10F−01

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DI−422
− DIAGNOSTICSCRUISE CONTROL SYSTEM
1996 TOYOTA T100 (RM449U)
DTC 12 Actuator Magnetic Clutch Circuit
CIRCUIT DESCRIPTION
This circuit turns on the magnetic clutch inside the actuator during cruise control operation according to the
signal from the ECU. If a malfunction occurs in the actuator or speed sensor, etc. during cruise control opera-
tion, the rotor shaft between the motor and control plate is released.
When the brake pedal is depressed, the stop light switch turns ON, supplying electrical power to the stop
light. Power supply to the magnetic clutch is mechanically cut and the magnetic clutch is turned OFF.
When driving downhill, if the vehicle speed exceeds the set speed by 15 km/h (9 mph), the ECU turns the
safety magnet clutch OFF. If the vehicle speed later drops to within 10 km/h (6 mph) above the set speed,
then cruise control at the set speed is resumed.
DTC No.Detection ItemTrouble Area
12Short in actuator magnetic clutch circuit.
Open (0.8 sec.) in actuator magnetic clutch circuit.
Actuator
Stop light switch
Wire harness
Cruise control ECU
WIRING DIAGRAM
DI351−02

Downloaded from www.Manualslib.com manuals search engine SA0FI−01
W00397
R04268
FA0026
SST SA−16
− SUSPENSION AND AXLEFRONT AXLE HUB (2WD)
1996 TOYOTA T100 (RM449U)
REMOVAL
1. REMOVE FRONT WHEEL
2. w/ ABS:
DISCONNECT ABS SPEED SENSOR FROM
STEERING KNUCKLE
3. REMOVE BRAKE CALIPER
(a) Remove the 2 brake caliper set bolts.
(b) Support the brake caliper securely.
4. CHECK AXLE HUB BEARING BACKLASH
(a) Remove the cap, cotter pin and lock cap.
(b) Using a dial indicator near the center of the axle hub and
check the backlash in the bearing shaft direction.
Maximum: 0.05 mm (0.0020 in.)
If the backlash is not within the specification replace the bear-
ing.
5. REMOVE AXLE HUB WITH DISC
(a) Using a 30 mm socket, remove the nut.
(b) Remove the axle hub with the disc together with the outer
bearing from the steering knuckle.
NOTICE:
Be careful not to drop the outer bearing.
6. REMOVE OIL SEAL AND INNER BEARING
(a) Using a screwdriver, pry out the oil seal.
NOTICE:
Be careful not to damage the ABS speed sensor rotor.
(b) Remove the inner bearing from the axle hub.
7. REMOVE DUST COVER
Remove the 3 bolts and dust cover.
8. DISCONNECT KNUCKLE ARM FROM STEERING
KNUCKLE
Remove the 2 bolts and disconnect the knuckle arm from the
steering knuckle.
9. REMOVE STEERING KNUCKLE
(a) Support the lower suspension arm with a jack.
(b) Remove the upper and lower cotter pins.
(c) Remove the upper and lower nuts.
(d) Using SST, disconnect the steering knuckle from the up-
per and lower ball joints.
SST 09628−62011
(e) Remove the steering knuckle.

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W00399
SA0326
R04292
SST
− SUSPENSION AND AXLEFRONT AXLE HUB (4WD)
SA−23
1996 TOYOTA T100 (RM449U)
REMOVAL
1. REMOVE FRONT WHEEL
2. w/ ABS:
DISCONNECT ABS SPEED SENSOR FROM
STEERING KNUCKLE
3. REMOVE BRAKE CALIPER
(a) Remove the 2 bolts and disconnect the knuckle arm with
brake line bracket from the steering knuckle.
(b) Remove the 2 brake caliper set bolts.
(c) Support the brake caliper securely.
4. REMOVE FLANGE
(a) Remove the grease cap from the flange.
(b) Remove the bolt.
(c) Remove the 6 mounting nuts and washers.
(d) Using a brass bar and hammer, tap on the bolts head and
remove the 6 cone washers.
(e) Install and tighten the 2 bolts and remove the flange.
(f) Remove the gasket.
5. REMOVE AXLE HUB WITH DISC
(a) Using a screwdriver, release the lock washer.
(b) Using SST, remove the lock nut.
SST 09607−60020
(c) Remove the lock washer and adjusting nut.
(d) Remove the claw washer.
(e) Remove the axle hub with the disc together with the outer
bearing.
NOTICE:
Be careful not to damage the ABS speed sensor rotor.
6. REMOVE OIL SEAL AND INNER BEARING
(a) Using a screwdriver, pry out the oil seal.
(b) Remove the inner bearing from the hub.

Downloaded from www.Manualslib.com manuals search engine BR0A2−04
R14754
4WD:
2WD:
Speed Sensor
Sensor Rotor
N·m (kgf·cm, ft·lbf) : Specified torque
5.0 (51, 44 in.·lbf)
8.0 (82, 71in.·lbf)
Speed Sensor
8.0 (82, 71in.·lbf)
5.0 (51, 44 in.·lbf)
BR−64
− BRAKEFRONT SPEED SENSOR
1669 Author: Date:
1996 TOYOTA T100 (RM449U)
FRONT SPEED SENSOR
COMPONENTS