Page 977 of 4087
BRAKE SYSTEM
BR±1
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Page 978 of 4087

GENERAL DESCRIPTION
BR03E±06
1. Care must be taken to replace each part properly as it could affect the \
performance of the brakesystem and result in a driving hazard. Replace the parts with parts of the same part number or
equivalent.
2. It is very important to keep parts and the area clean when repairing the\
brake system.
3. If the vehicle is equipped with a mobile communication system, refer to the precaution \
in the IN section.
DESCRIPTION
BR03F±03
The service brakes consist of a foot brake which changes rotational energy to therma\
l energy to stop the
vehicle while it is being driven and a parking brake to keep the vehicle from m\
oving while it is parked.
OPERATION
FOOT BRAKE
BR03G±06
When the brake pedal is depressed, a vacuum builds up in the booster whi\
ch amplifies the pedal force,
pressing on the piston in the master cylinder. The piston movement raises the hydraulic pressure in the
cylinder. This hydraulic pressure is then applied to each respective brake cylin\
der, and acts to press the
brake pads against the rotating discs. The resulting friction converts the ro\
tational energy to thermal ener-
gy, stopping the vehicle.
BR±2±
BRAKE SYSTEM OPERATION
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Page 979 of 4087

GENERAL DESCRIPTION
BR03E±06
1. Care must be taken to replace each part properly as it could affect the \
performance of the brakesystem and result in a driving hazard. Replace the parts with parts of the same part number or
equivalent.
2. It is very important to keep parts and the area clean when repairing the\
brake system.
3. If the vehicle is equipped with a mobile communication system, refer to the precaution \
in the IN section.
DESCRIPTION
BR03F±03
The service brakes consist of a foot brake which changes rotational energy to therma\
l energy to stop the
vehicle while it is being driven and a parking brake to keep the vehicle from m\
oving while it is parked.
OPERATION
FOOT BRAKE
BR03G±06
When the brake pedal is depressed, a vacuum builds up in the booster whi\
ch amplifies the pedal force,
pressing on the piston in the master cylinder. The piston movement raises the hydraulic pressure in the
cylinder. This hydraulic pressure is then applied to each respective brake cylin\
der, and acts to press the
brake pads against the rotating discs. The resulting friction converts the ro\
tational energy to thermal ener-
gy, stopping the vehicle.
BR±2±
BRAKE SYSTEM OPERATION
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Page 980 of 4087
PARKING BRAKE
BR03H±04
When the parking brake lever is pulled up, the parking brake shoe lever is p\
ulled via the parking brake wire.
This causes the shoe strut to push the front shoe, which expands and is pres\
sed against the disc. If the
parking brake lever continues to be pulled up, the contact point of the parking\
brake shoe lever and shoe
strut then becomes the fulcrum so that the parking brake shoe lever causes th\
e rear shoe to expand. This
results in the disc being locked by the front shoe and rear shoe.
±
BRAKE SYSTEM OPERATIONBR±3
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Page 981 of 4087
PREPARATION
SST (SPECIAL SERVICE TOOLS)
BR03J±04
RECOMMENDED TOOLS
BR0EB±01
BR±4±
BRAKE SYSTEM PREPARATION
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Page 982 of 4087
EQUIPMENT
BR03K±03\
\
\
Torque wrench
\
\
\
Micrometer
Brake disc
\
\
\
Dial indicator
Brake disc
\
\
\
Vernier calipers
Brake disc
LUBRICANT
BR03L±03
Item
Capacity
Classification
Brake fluid ±± SAEJ1703 or FMVSS No. 116, DOT 3
±
BRAKE SYSTEM PREPARATIONBR±5
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Page 983 of 4087
TROUBLESHOOTING
BR03M±06
Use the table below to help you find the cause of the problem. The numbers i\
ndicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
BR±21, 29, 3
7
BR±7
BR±12 BR±49
BR±11
BR±19
BR±44
BR±44 4BR±21, 29, 37
BR±2 1, 29, 37
BR±2 1, 29, 37
BR±2 1, 29, 37
BR±2
1, 29, 37
BR±2 1, 29, 37
BR±2 1, 29, 37
BR±2 1, 29, 37
BR±2 1, 29, 37
BR±2 1, 29, 37
BR±2 1, 29, 37
BR±2 1, 29, 37BR±8
BR±6±
BRAKE SYSTEM TROUBLESHOOTING
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Page 984 of 4087

CHECK AND ADJUSTMENT
BR0EC±07
BRAKE PEDAL CHECK AND
ADJUSTMENT
1. CHECK THAT PEDAL HEIGHT IS CORRECT
Pedal height from asphalt sheet:150.4±160.4 mm (5.92±6.31 in.)
If the pedal height is incorrect, adjust it.
2. IF NECESSARY, ADJUST PEDAL HEIGHT
(a) Disconnect the connector from the stop light switch.
(b) Loosen the stop light switch lock nut and remove the stop light switch.
(c) Loosen the push rod lock nut.
(d) Adjust the pedal height by turning the pedal push rod.
(e) Tighten the push rod lock nut.
Torque: 25 N Vm (260 kgf Vcm, 19 ft Vlbf)
(f) Install the stop light switch and turn it until it lightly contacts
the pedal stopper.
(g) Turn the stop light switch back one turn.
(h) Check the clearance (A) between stop light switch and pedal.
Clearance:
0.5±2.4 mm (0.02±0.09 in.)
(i) Tighten the stop light switch lock nut.
(j) Connect the connector to the stop light switch.
(k) Check that the stop lights come on when the brake pedal isdepressed, and go off when the brake pedal is released.
(l) After adjusting the pedal height, check the pedal free±play.
HINT: If clearance (A) between the stop light switch and the
brake pedal stopper has been adjusted correctly, the pedal
freeplay will meet the specifications.
3. CHECK THAT PEDAL FREEPLAY IS CORRECT, AS SHOWN
(a) Stop the engine and depress the brake pedal several times until there is no more vacuum left in the booster.
(b) Push in the pedal by hand until the beginning of the second point of resistance is felt, then measure the distance, as
shown.
Pedal freeplay:
1±6 mm (0.04±0.24 in.)
If incorrect, check the stop light switch clearance. And if the
clearance is OK, then troubleshoot the brake system.
HINT: The freeplay to the first point of resistance is due to the
play between the clevis and pin. It is 1±3 mm (0.04±0.12 in.)
on the pedal.
±
BRAKE SYSTEM CHECK AND ADJUSTMENTBR±7
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