1996 TOYOTA RAV4 Service Repair Manual

BR035−02
W01808
R10635
R10636
R10637
BR−26
− BRAKEFRONT BRAKE CALIPER
1996 RAV4 (RM447U)
INSPECTION
1. MEASURE PAD LINING THICKNESS
Using a ruler, measure the pad lining thickness.
Standard thickness: 12.0 mm (0.472 in.)
Minimum thickness: 1.0 mm (0.039 in.)
Replace the pad if the pad’s thickness is at the minimum thick-
ness or less, or if the pad has severe and uneven wear.
2. MEASURE DISC THICKNESS
Using a micrometer, measure the disc thickness.
Standard thickness: 18.0 mm (0.709 in.)
Minimum thickness: 16.0 mm (0.630 in.)
Replace the disc if the thickness of the disc is at the minimum
thickness or less. Replace the disc or grind it on a lathe if it is
scored or is worn unevenly.
3. MEASURE DISC RUNOUT
Using a dial indicator, measure the disc runout at a position 10
mm (0.39 in.) from the outside edge.
Maximum disc runout: 0.05 mm (0.0020 in.)
If the disc’s runout is at the maximum value or greater, check the
bearing play in the axial direction and check the axle hub runout
(See page SA−10). If the bearing play and axle hub runout are
not abnormal, adjust the disc runout or grind it on a ”On−Car”
brake lathe.
4. IF NECESSARY, ADJUST DISC RUNOUT
(a) Remove the 2 bolts and torque plate from the knuckle.
(b) Remove the hub nuts and the disc. Reinstall the disc in
the position turned 1/5 from its original position on the
hub. Install and torque the hub nuts.
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)
(c) Remeasure the disc runout. Make a note of the runout
and the disc’s position on the hub.
(d) Repeat (b) and (c) until the disc is installed on the 3 re-
maining hub positions.
If the minimum runout recorded in (b) and (c) is less
than 0.05 mm (0.0020 in.), install the disc in that
position.
If the minimum runout recorded in (b) and (c) is
greater than 0.05 mm (0.0020 in.), replace the disc
and repeat step 3.
(e) Install the torque plate and torque the mounting bolts.
Torque: 107 N·m (1,090 kgf·cm, 79 ft·lbf)

BR036−02
− BRAKEFRONT BRAKE CALIPER
BR−27
1996 RAV4 (RM447U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page BR−25).
NOTICE:
Apply lithium soap base glycol grease to the parts indicated by the arrows (See page BR−23).

BR037−02
BR−28
− BRAKEFRONT BRAKE CALIPER
1996 RAV4 (RM447U)
INSTALLATION
Installation is in the reverse order of removal (See page BR−24).
AFTER INSTALLATION, FILL BRAKE RESERVOIR WITH BRAKE FLUID, BLEED BRAKE SYSTEM
(See page BR−4) AND CHECK FOR LEAKS

BR03E−02
W01385
PinBoot
 Cup Bleeder Plug
Piston Spring
AdjusterWheel Cylinder
Rear Shoe
Parking Brake Lever
 C−washer
 E−ring
Automatic
Adjusting
Lever
Adjusting
Lever
Spring Anchor Spring
Shoe Hold−down
Spring Return Spring
Front ShoeBoot
Piston Cup
Cup15 (155, 11)8.3 (85, 74 in.·lbf)
10 (100, 7)
N·m (kgf·cm, ft·lbf) : Specified torque
 Non−reusable part
Lithium soap base glycol grease
High temperature grease
− BRAKEREAR DRUM BRAKE
BR−29
1996 RAV4 (RM447U)
REAR DRUM BRAKE
COMPONENTS

BR0M7−01
R10719
R00285
R10696
SST
R10720
SST BR−30
− BRAKEREAR DRUM BRAKE
1996 RAV4 (RM447U)
REMOVAL
1. INSPECT SHOE LINING THICKNESS
Remove the inspection hole plug, and check the shoe lining
thickness through the hole.
If less than minimum, replace the shoes.
Minimum thickness: 1.0 mm (0.039 in.)
2. REMOVE REAR WHEEL
3. REMOVE BRAKE DRUM
HINT:
If the brake drum cannot be removed easily, do the following
steps.
(a) Insert a bent wire or an equivalent through the hole in the
brake drum, and hold the automatic adjusting lever away
from the adjuster.
(b) Using a screwdriver, reduce the brake shoe adjustment
by turning the adjuster.
HINT:
At the time of installation, please refer to the following item.
Align the hub’s large hole next to the small hole in the clockwise
direction with the drum’s plug hole.
4. REMOVE FRONT SHOE
(a) Using SST, remove the return spring.
SST 09703−30010
(b) Using SST, remove the shoe hold−down spring, cups and
pin.
SST 09718−00010
(c) Disconnect the anchor spring from the front shoe and re-
move the front shoe.
(d) Remove the anchor spring from the rear shoe.

Z13290
SST
R10699
R10700
SST
BR0370
− BRAKEREAR DRUM BRAKE
BR−31
1996 RAV4 (RM447U)
5. REMOVE REAR SHOE
(a) Using SST, remove the shoe hold−down spring, cups and
pin.
SST 09718−00010
(b) Using a screwdriver, disconnect the parking brake cable
from the anchor plate.
(c) Using pliers, disconnect the parking brake cable from the
lever and remove the rear shoe together with the adjuster.
6. REMOVE ADJUSTER FROM REAR SHOE
(a) Remove the adjusting lever spring.
(b) Remove the adjuster together with the return spring.
7. DISCONNECT BRAKE LINE FROM WHEEL CYL-
INDER
Using SST, disconnect the brake line. Use a container to catch
the brake fluid.
SST 09023−00100
Torque: 15 N·m (155 kgf·cm, 11 ft·lbf)
8. REMOVE WHEEL CYLINDER
Remove the 2 bolts and the wheel cylinder.
Torque: 10 N·m (100 kgf·cm, 7 ft·lbf)
9. DISASSEMBLE WHEEL CYLINDER
Remove these parts from the wheel cylinder.
2 boots
2 pistons
2 piston cups
Spring

BR0M8−01
BR1542
BR0046
BR1543
BR−32
− BRAKEREAR DRUM BRAKE
1996 RAV4 (RM447U)
INSPECTION
1. INSPECT DISASSEMBLED PARTS
Inspect the disassembled parts for wear, rust or damage.
2. MEASURE BRAKE SHOE LINING THICKNESS
Using a ruler, measure the shoe lining thickness.
Standard thickness: 5.0 mm (0.197 in.)
Minimum thickness: 1.0 mm (0.039 in.)
If the shoe lining is less than the minimum or shows signs of un-
even wear, replace the brake shoes.
HINT:
If a brake shoe needs replacing, the brake shoes must be re-
placed as a set.
3. MEASURE BRAKE DRUM INSIDE DIAMETER
Using a vernier calipers, measure the inside diameter of the
drum.
Standard inside diameter: 228.6 mm (9.000 in.)
Maximum inside diameter: 230.6 mm (9.079 in.)
If the drum is scored or worn, the brake drum may be lathed to
the maximum inside diameter.
4. INSPECT REAR BRAKE LINING AND DRUM FOR
PROPER CONTACT
If the contact between the brake lining and drum is improper, re-
pair the lining with a brake shoe grinder, or replace the brake
shoe assembly.

BR0M9−01
Z13455
− BRAKEREAR DRUM BRAKE
BR−33
1996 RAV4 (RM447U)
INSTALLATION
Installation is in the reverse order of removal (See page
BR−30).
1. AFTER INSTALLATION, FILL BRAKE RESERVOIR
WITH BRAKE FLUID, BLEED BRAKE SYSTEM (See
page BR−4) AND CHECK FOR LEAKS
NOTICE:
Apply lithium soap base glycol grease and high tempera-
ture grease to the parts indicated by the arrows (See page
BR−29).
2. CHECK OPERATION OF AUTOMATIC ADJUSTING
MECHANISM
(a) Move the parking brake lever of the rear shoe back and
forth. Check that the adjuster turns.
If the adjuster does not turn, check incorrect installation of the
rear brake.
(b) Adjust the adjuster length to the shortest possible
amount.
(c) Install the brake drum.
(d) Pull the parking brake lever all the way up until a clicking
sound can no longer be heard.
3. CHECK CLEARANCE BETWEEN BRAKE SHOES AND
DRUM
(a) Remove the brake drum.
(b) Measure the brake drum inside diameter and diameter of
the brake shoes. Check that the difference between the
diameters is the correct shoe clearance.
Shoe clearance: 0.6 mm (0.024 in.)
If incorrect, check the parking brake system.