1996 TOYOTA T100 engine

Downloaded from www.Manualslib.com manuals search engine R12874
BR08Q−01
R12851
R12852
Z03605
BR−4
− BRAKEBRAKE FLUID
1609 Author: Date:
1996 TOYOTA T100 (RM449U)
BRAKE FLUID
BLEEDING
HINT:
If any work is done on the brake system or if air is suspected in
the brake lines, bleed the system of air.
NOTICE:
Do not let brake fluid remain on a painted surface. Wash it
off immediately.
1. FILL BRAKE RESERVOIR WITH BRAKE FLUID
Check the fluid level in the reservoir after bleeding each wheel.
Add fluid, if necessary.
2. BLEED MASTER CYLINDER
HINT:
If the master cylinder was disassembled or if the reservoir be-
comes empty, bleed the air from the master cylinder.
(a) Disconnect the brake lines from the master cylinder.
(b) Slowly depress the brake pedal and hold it.
(c) Block off the outlet plug with your finger, and release the
brake pedal.
(d) Repeat (b) and (c) 3 or 4 times.
3. CONNECT VINYL TUBE TO WHEEL CYLINDER
BLEEDER PLUG
Insert the other end of the tube in a half−full container of brake
fluid.
HINT:
Begin air bleeding from the wheel cylinder with the longest hy-
draulic line.
4. BLEED BRAKE LINE
(a) Slowly depress the brake pedal several times.

Downloaded from www.Manualslib.com manuals search engine − BRAKEBRAKE FLUID
BR−5
1610 Author: Date:
1996 TOYOTA T100 (RM449U)
(b) While an assistant depresses the pedal, loosen the
bleeder plug until fluid starts to run out. Then close the
bleeder plug.
Torque: (bleeder plug) 11 N·m (110 kgf·cm, 8 ft·lbf)
(c) Repeat this procedure until there are no more air bubbles
in the fluid.
5. REPEAT PROCEDURE FOR EACH WHEEL
6. BLEED LSP & BV

Downloaded from www.Manualslib.com manuals search engine BR3295
Stop Light Switch
Pedal Height Push RodBR08R−01
BR4980
A BR−6
− BRAKEBRAKE PEDAL
1611 Author: Date:
1996 TOYOTA T100 (RM449U)
BRAKE PEDAL
ON−VEHICLE INSPECTION
1. CHECK PEDAL HEIGHT
Pedal height from asphalt sheet:
Extra cab 4WD:
146.7 − 156.7 mm (5.776 − 6.169 in.)
Except extra cab 4WD:
149.7 − 159.7 mm (5.894 − 6.287 in.)
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·m (260 kgf·cm, 19 ft·lbf)
(f) Install the stop light switch and turn it until it lightly con-
tacts 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 (0.020 − 0.094 in.)
(i) Tighten the stop light switch lock nut.
(j) Check the stop lights come on when the brake pedal is de-
pressed, and go off when the brake pedal is released.
(k) After adjusting the pedal height, check the pedal freeplay.
HINT:
If clearance (A) between the stop light switch and the pedal
stopper has been adjusted correctly, the pedal freeplay will
meet the specifications.

Downloaded from www.Manualslib.com manuals search engine BR3296
Push Rod
Pedal Freeplay
3 − 6 mm
BR3297
Pedal Reserve Distance
a
− BRAKEBRAKE PEDAL
BR−7
1612 Author: Date:
1996 TOYOTA T100 (RM449U)
3. CHECK PEDAL FREEPLAY
(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 second resistance be-
gins to be felt. Measure the distance as shown in the il-
lustration.
Pedal freeplay: 3 − 6 mm (0.12 − 0.24 in.)
HINT:
The freeplay to the 1st resistance is due to the play between the
clevis and pin. This is magnified up to 1 − 3 mm (0.04 − 0.12 in.)
at the pedal.
4. CHECK PEDAL RESERVE DISTANCE
Release the parking brake.
With the engine running, depress the pedal and measure the
pedal reserve distance, as shown.
Pedal reserve distance, ’a’, at 490 N (50 kgf, 110.2 lbf):
2WD 1 ton (STD cab): More than 78 mm (3.07 in.)
2WD 0.5 ton/4WD (STD cab):
More than 73 mm (2.87 in.)
4WD (Extra cab): More than 70 mm (2.76 in.)
If incorrect, troubleshoot the brake system.

Downloaded from www.Manualslib.com manuals search engine BR0080
BR08S−02
BR0246
R12820
BR−8
− BRAKEPARKING BRAKE LEVER
1613 Author: Date:
1996 TOYOTA T100 (RM449U)
PARKING BRAKE LEVER
ON−VEHICLE INSPECTION
1. CHECK PARKING BRAKE LEVER TRAVEL
Pull the parking brake lever all the way up, and count the num-
ber of clicks.
Parking brake lever travel at 196 N (20 kgf, 44.1 lbf):
11 − 17 clicks
2. 2WD:
IF NECESSARY, ADJUST PARKING BRAKE
HINT:
Before adjusting the parking brake, make sure that the rear
brake shoe clearance has been adjusted.
(a) Tighten the adjusting nut until the travel is correct.
Then tighten the lock nut.
(b) After adjusting the parking brake, confirm that the rear
brakes are not dragging.
3. 4WD:
IF NECESSARY, ADJUST PARKING BRAKE
HINT:
Before adjusting the parking brake, make sure that the rear
brake shoe clearance has been adjusted.
(a) Tighten 1 of the adjusting nuts of the intermediate lever
while loosening the other one until the travel is correct.
Tighten the 2 adjusting nuts.
(b) After adjusting the parking brake, confirm that the bell-
crank stopper screw comes into contact with the backing
plate.

Downloaded from www.Manualslib.com manuals search engine BR08T−02
F00667
F00667
w/o ABS:
w/ ABS:Master Cylinder
3−Way UnionBrake Booster  Gasket
Clamp
 Non−reusable partCheck Valve Bracket Gasket
Brake Booster
Clamp
3−Way Union
N·m (kgf·cm, ft·lbf) : Specified torque
15 (155, 11)
13 (130, 9)
13 (130, 9)
15 (155, 11)
Master Cylinder
− BRAKEBRAKE MASTER CYLINDER
BR−9
1614 Author: Date:
1996 TOYOTA T100 (RM449U)
BRAKE MASTER CYLINDER
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine R14642
Cap
Boot Strainer
Reservoir
No.1 Piston and Spring Reservoir Set Screw
Grommet
Snap Ring
Piston Stopper Bolt Gasket w/o ABS:
w/ ABS:
Cap
Strainer
Reservoir
GrommetGrommetNo.1 Piston and Spring
Boot
Snap Ring No.2 Piston and Spring
No.2 Piston and Spring
Piston Stopper Bolt Gasket Cylinder Body Cylinder Body
Reservoir Set Screw
Grommet
Lithium soap base glycol greaseNon−reusable part N·m (kgf·cm, ft·lbf) : Specified torque
1.7 (17.5, 15.2 in.·lbf)
10 (100, 7)
1.7 (17.5, 15.2 in.·lbf)
10 (100, 7)
BR−10
− BRAKEBRAKE MASTER CYLINDER
1615 Author: Date:
1996 TOYOTA T100 (RM449U)

Downloaded from www.Manualslib.com manuals search engine BR08U−01
R12875
SST
R12876
− BRAKEBRAKE MASTER CYLINDER
BR−11
1996 TOYOTA T100 (RM449U)
REMOVAL
1. DISCONNECT LEVEL WARNING SWITCH
CONNECTOR
2. TAKE OUT FLUID WITH SYRINGE
NOTICE:
Do not let brake fluid remain on a painted surface. Wash it
off immediately.
3. DISCONNECT BRAKE LINES
Using SST, disconnect the brake lines from the master cylinder
and 3−way union.
SST 09751−36011
4. REMOVE MASTER CYLINDER
(a) Remove the 4 nuts and 3−way union.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
(b) Remove the clamp.
(c) w/ ABS:
Remove the check valve bracket.
(d) Remove the master cylinder and gasket from the brake
booster.