1996 TOYOTA RAV4 Service Repair Manual

BR02S−02
R10718
BR−18
− BRAKEBRAKE BOOSTER ASSEMBLY
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE MASTER CYLINDER (See page BR−9)
2. REMOVE CHARCOAL CANISTER
3. DISCONNECT VACUUM HOSE FROM BRAKE
BOOSTER
4. REMOVE PEDAL RETURN SPRING
5. REMOVE CLIP AND CLEVIS PIN
6. REMOVE BRAKE BOOSTER
(a) Remove the 4 nuts and clevis.
(b) Pull out the brake booster and gasket.

BR0M3−01
F03521
SST
Gasket
N00744
SST
− BRAKEBRAKE BOOSTER ASSEMBLY
BR−19
1996 RAV4 (RM447U)
INSTALLATION
1. INSTALL BRAKE BOOSTER
(a) Install the booster and a new gasket.
(b) Install the clevis to the operating rod.
(c) Install and torque the booster installation nuts.
Torque:
13 N·m (130 kgf·cm, 9 ft·lbf)
(d) Insert the clevis pin into clevis, brake pedal, and install the
clip to the clevis pin.
(e) Install the pedal return spring.
2. ADJUST LENGTH OF BOOSTER PUSH ROD
(a) Install a new gasket on the master cylinder.
(b) Set the SST on the gasket, and lower the pin until its tip
slightly touches the piston.
SST 09737−00010
(c) Turn the SST upside down, and set it on the booster.
SST 09737−00010
(d) Measure the clearance between the booster push rod
and pin head (SST).
Clearance: 0 mm (0 in.)
(e) Adjust the booster push rod length until the push rod
slightly touches the pin head.
3. INSTALL CHARCOAL CANISTER TO ORIGINAL POSI-
TION
4. INSTALL MASTER CYLINDER
5. CONNECT VACUUM HOSE TO BRAKE BOOSTER
6. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND
BLEED BRAKE SYSTEM (See page BR−4)
7. M/T:
BLEED CLUTCH SYSTEM
8. CHECK FOR LEAKS
9. CHECK AND ADJUST BRAKE PEDAL
(See page BR−6)
Check and adjust the brake pedal, then tighten the clevis lock
nut.
Torque:
25 N·m (260 kgf·cm, 19 ft·lbf)
10. DO OPERATIONAL CHECK (See page BR−16)

BR02Y−11
BR−20
− BRAKEFRONT BRAKE PAD
1996 RAV4 (RM447U)
FRONT BRAKE PAD
COMPONENTS

BR0M4−01
R10627
R10628
− BRAKEFRONT BRAKE PAD
BR−21
1996 RAV4 (RM447U)
REPLACEMENT
1. REMOVE FRONT WHEEL
Remove the wheel and temporarily fasten the disc with the hub
nuts.
2. INSPECT PAD LINING THICKNESS
Check the pad thickness through the caliper inspection hole
and replace the pads if they are not within the specification.
Minimum thickness: 1.0 mm (0.039 in.)
3. LIFT UP CALIPER
(a) Remove the flexible hose from the shock absorber brack-
et.
(b) Hold the sliding pin on the bottom and loosen the installa-
tion bolt.
(c) Remove the installation bolt.
(d) Lift up the caliper and suspend it securely.
HINT:
Do not disconnect the flexible hose from the caliper.
4. REMOVE THESE PARTS:
2 brake pads
4 anti−squeal shims
4 pad support plates
NOTICE:
The 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−26)
6. INSTALL 4 PAD SUPPORT PLATES

R10629
BR−22
− BRAKEFRONT BRAKE PAD
1996 RAV4 (RM447U)
7. INSTALL NEW PADS
NOTICE:
When replacing worn pads, the anti−squeal shims must be
replaced together with the pads.
(a) Apply disc brake grease to both side of the inner anti−
squeal shims (See page BR−20).
(b) Install the anti−squeal shim to the inner pad.
(c) Install the inner pad with pad wear indicator plate facing
upward.
(d) Install the outer pad.
NOTICE:
There should be no oil or grease adhering to the friction
surfaces of the pads or the disc.
8. INSTALL CALIPER
(a) Draw out a small amount of brake fluid from the reservoir.
(b) Press in the piston with a hammer handle or an equiva-
lent.
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) Install the caliper.
(d) Hold the sliding pin and torque the installation bolt.
Torque: 26 N·m (270 kgf·cm, 20 ft·lbf)
(e) Install the flexible hose bracket.
Torque: 33 N·m (340 kgf·cm, 25 ft·lbf)
9. INSTALL FRONT WHEEL
10. CHECK THAT FLUID LEVEL IS AT MAX LINE

BR032−14
− BRAKEFRONT BRAKE CALIPER
BR−23
1996 RAV4 (RM447U)
FRONT BRAKE CALIPER
COMPONENTS

BR0M5−01
R10630
BR−24
− BRAKEFRONT BRAKE CALIPER
1996 RAV4 (RM447U)
REMOVAL
1. DISCONNECT FLEXIBLE HOSE
(a) Remove the union bolt and 2 gaskets from the caliper,
then disconnect the flexible hose from the caliper.
Torque: 30 N·m (310 kgf·cm, 22 ft·lbf)
HINT:
At the time of installation, please refer to the following item.
Install the flexible hose lock securely in the lock hole in the cali-
per.
(b) Use a container to catch the brake fluid as it drains out.
2. REMOVE CALIPER
(a) Hold the sliding pin and loosen the 2 installation bolts.
Torque: 26 N·m (270 kgf·cm, 20 ft·lbf)
(b) Remove the 2 installation bolts.
(c) Remove the caliper from the torque plate.
3. REMOVE THESE PARTS:
2 brake pads with anti−squeal shims
4 pad support plates

BR0M6−01
R10631
R10633
R10634
− BRAKEFRONT BRAKE CALIPER
BR−25
1996 RAV4 (RM447U)
DISASSEMBLY
1. REMOVE CYLINDER BOOT SET RING AND
CYLINDER BOOT
Using a screwdriver, remove the cylinder boot set ring and cylin-
der boot.
2. REMOVE PISTON
(a) Put a piece of cloth or equivalent between the piston and
the 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.
3. REMOVE PISTON SEAL
Using a screwdriver, remove the piston seal.
4. REMOVE SLIDING PINS AND DUST BOOTS
(a) Remove the 2 sliding pins from the torque plate.
NOTICE:
At the time of reassembly, please refer to the following
item.
Insert the sliding pin with the sliding bushing into the upper
side.
(b) Using a screwdriver and a hammer, tap out the 2 dust
boots.
HINT:
At the time of reassembly, please refer to the following item.
Use a 21 mm socket and 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.