1996 TOYOTA T100 engine

Downloaded from www.Manualslib.com manuals search engine BR08V−02
BR2248
R12218
Soft Jaws
R12217
Soft Jaws BR−12
− BRAKEBRAKE MASTER CYLINDER
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. REMOVE MASTER CYLINDER BOOT
Using a screwdriver, remove the master cylinder boot.
NOTICE:
At the time of reassembly, please refer to the following
item.
Facing the UP mark on the master cylinder boot upwards,
install the cylinder boot to the master cylinder.
2. REMOVE RESERVOIR
(a) Remove the set screw and pull out the reservoir.
Torque: 1.7 N·m (17.5 kgf·cm, 15.2 in.·lbf)
(b) Remove the cap and strainer from the reservoir.
3. REMOVE 2 GROMMETS
4. PLACE CYLINDER IN VISE
5. REMOVE PISTON STOPPER BOLT
Using a screwdriver, push the pistons in all the way and remove
the piston stopper bolt and gasket.
HINT:
Tape the screwdriver tip before use.
Torque: 10 N·m (100 kgf·cm, 7 ft·lbf)
6. REMOVE 2 PISTONS AND SPRINGS
(a) Push in the piston with a screwdriver and remove the
snap ring with snap ring pliers.
HINT:
Tape the screwdriver tip before use.
(b) Remove the No.1 piston and spring by hand, pulling
straight out, not at an angle.
NOTICE:
If pulled out and installed at an angle, there is a possibility
that the cylinder bore could be damaged.
NOTICE:
At the time of reassembly, please refer to the following
item. Be careful not to damage the rubber lips on the pis-
tons.

Downloaded from www.Manualslib.com manuals search engine R12236
A
− BRAKEBRAKE MASTER CYLINDER
BR−13
1996 TOYOTA T100 (RM449U)
(c) Place a rag and 2 wooden blocks on the work table, and
lightly tap the cylinder flange against the block edges until
the No.2 piston drops out of cylinder.
HINT:
Make sure the distance (A) from the rag to the top of the blocks
is at least 100 mm (3.94 in.).

Downloaded from www.Manualslib.com manuals search engine BR08W−01
BR−14
− BRAKEBRAKE MASTER CYLINDER
1996 TOYOTA T100 (RM449U)
INSPECTION
HINT:
Clean the disassembled parts with compressed air.
1. INSPECT CYLINDER BORE FOR RUST OR SCORING
2. INSPECT CYLINDER FOR WEAR OR DAMAGE
If necessary, clean or replace the cylinder.

Downloaded from www.Manualslib.com manuals search engine BR08X−01
− BRAKEBRAKE MASTER CYLINDER
BR−15
1996 TOYOTA T100 (RM449U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page BR−12).
NOTICE:
Apply lithium soap base glycol grease to the rubber parts indicated by the arrows
(See page BR−9).

Downloaded from www.Manualslib.com manuals search engine BR08Y−01
BR−16
− BRAKEBRAKE MASTER CYLINDER
1996 TOYOTA T100 (RM449U)
INSTALLATION
Installation is in the reverse order of removal (See page BR−11).
1. BEFORE INSTALLATION, ADJUST LENGTH OF BRAKE BOOSTER PUSH ROD
(See page BR−20)
2. AFTER INSTALLATION, FILL BRAKE RESERVOIR WITH BRAKE FLUID. AND BLEED BRAKE
SYSTEM (See page BR−4)
3. CHECK FOR LEAKS, CHECK AND ADJUST BRAKE PEDAL (See page BR−6)

Downloaded from www.Manualslib.com manuals search engine BR2237
BR08Z−01
BR2238
GOOD NO GOOD
1st2nd3rd
− BRAKEBRAKE BOOSTER ASSEMBLY
BR−17
1622 Author: Date:
1996 TOYOTA T100 (RM449U)
BRAKE BOOSTER ASSEMBLY
ON−VEHICLE INSPECTION
1. OPERATING CHECK
(a) Depress the brake pedal several times with the engine off,
and check that there is no change in the pedal reserve
distance.
(b) Depress the brake pedal and start engine. If the pedal
goes down slightly, operation is normal.
2. AIR TIGHTNESS CHECK
(a) Start the engine and stop it after 1 or 2 minutes. Depress
the brake pedal several times slowly.
If the pedal goes down furthest the 1st time, but gradually rises
after the 2nd or 3rd time, the booster is air tight.
(b) Depress the brake pedal while the engine is running, and
stop it with the pedal depressed. If there is no change in
pedal reserve travel after holding the pedal for 30 se-
conds, the booster is air tight.

Downloaded from www.Manualslib.com manuals search engine BR090−02
R14753
R14753
Master Cylinder
Non−reusable part 3−Way UnionBrake Booster Gasket
Clevis
Clip Clevis Pin
ClampGasket
N·m (kgf·cm, ft·lbf) : Specified torque
15 (155, 11)
13 (130, 9)
25 (260, 19)13 (130, 9)
BR−18
− BRAKEBRAKE BOOSTER ASSEMBLY
1996 TOYOTA T100 (RM449U)
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine BR091−01
BR3285
− BRAKEBRAKE BOOSTER ASSEMBLY
BR−19
1996 TOYOTA T100 (RM449U)
REMOVAL
1. REMOVE MASTER CYLINDER (See page BR−11)
2. DISCONNECT VACUUM HOSE FROM BRAKE
BOOSTER
3. REMOVE PEDAL RETURN SPRING
4. REMOVE CLIP AND CLEVIS PIN
5. REMOVE BRAKE BOOSTER
(a) Remove the 4 nuts and clevis.
(b) Pull out the brake booster and gasket.