1996 TOYOTA T100 engine

Downloaded from www.Manualslib.com manuals search engine BR092−01
BR3286
F03521
SST
Gasket
Z03607
SST BR−20
− BRAKEBRAKE BOOSTER ASSEMBLY
1996 TOYOTA T100 (RM449U)
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) Install the clevis pin into the clevis and 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 light-
ly touches the pin head.
3. INSTALL MASTER CYLINDER (See page BR−16)
4. CONNECT VACUUM HOSE TO BRAKE BOOSTER
5. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND
BLEED BRAKE SYSTEM (See page BR−4)
6. CHECK FOR FLUID LEAKAGE
7. 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)
8. DO OPERATIONAL CHECK (See page BR−17)

Downloaded from www.Manualslib.com manuals search engine BR093−03
Z18924
PadAnti−Squeal Spring
Pad Wear Indicator Plate 1 ton :
Anti−Squeal Shim Pad Support PlateInner Anti Squeal Shim
Disc brake grease
Pad Pad Support Plate
Pad Wear
Indicator Plate 0.5 ton :Bleeder Plug
Dust Boot
Sliding Bushing
Brake Caliper
Dust Boot
Set Ring Torque PlatePiston
Piston Seal
BootGasket

Anti−Squeal Shim

Gasket

Brake Caliper
Piston Seal
Piston
Boot
Dust Boot  Bleeder Plug
Torque PlateSliding Pin
Lithium soap base glycol grease
Non−reusable part 
39 (400, 29)
36 (370, 27)
N·m (kgf·cm, ft·lbf)
: Specified torque
− BRAKEFRONT BRAKE PAD (2WD)
BR−21
1626 Author: Date:
1996 TOYOTA T100 (RM449U)
FRONT BRAKE PAD (2WD)
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine BR094−01
BR3082
R04837
BR3312
BR−22
− BRAKEFRONT BRAKE PAD (2WD)
1996 TOYOTA T100 (RM449U)
REPLACEMENT
1. REMOVE FRONT WHEEL
Remove the wheel and temporarily fasten the disc with hub
nuts.
2. INSPECT PAD LINING THICKNESS
Check the pad thickness through the caliper inspection hole
and replace pads if not within specification.
Minimum thickness: 1.0 mm (0.039 in.)
3. LIFT UP CALIPER
(a) Remove the installation bolt.
(b) Lift up the caliper and suspend it securely.
HINT:
Do not disconnect the flexible hose from the caliper.
4. REMOVE THESE PARTS:
1 ton:
2 anti−squeal springs
2 brake pads
2 (1 ton) / 4 (0.5 ton) anti−squeal shims
2 pad wear indicator plates
4 pad support plates
NOTICE:
The anti−squeal springs (1 ton) and 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−30)
6. INSTALL 4 PAD SUPPORT PLATES
7. INSTALL NEW PADS
NOTICE:
When replacing worn pads, the anti−squeal shims and
wear indicator plates must be replaced together with the
pads.
(a) Install a pad wear indicator plate to the pad.
(b) 1 ton:
Install the anti−squeal shim to each pad.
(c) 0.5 ton:
Install the 4 anti−squeal shims to each pad.
HINT:
Apply disc brake grease to both sides of inner anti−squeal
shims (See page BR−21).

Downloaded from www.Manualslib.com manuals search engine R05057
R05256
− BRAKEFRONT BRAKE PAD (2WD)
BR−23
1996 TOYOTA T100 (RM449U)
(d) Install the 2 pads so that the wear indicator plate is facing
underneath.
NOTICE:
Do not allow oil or grease on the rubbing face.
8. INSTALL CALIPER
(a) Draw out a small amount of brake fluid from the reservoir.
(b) Press in piston with a hammer handle or equivalent.
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) Insert the brake caliper carefully so the boot is not
wedged.
(d) Install and torque the installation bolts.
Torque:
1 ton: 39 N·m (400 kgf·cm, 29 ft·lbf)
Torque:
0.5 ton: 36 N·m (370 kgf·cm, 27 ft·lbf)
9. INSTALL FRONT WHEEL
10. CHECK THAT FLUID LEVEL IS AT MAX LINE

Downloaded from www.Manualslib.com manuals search engine BR095−02
Z18922Disc brake greaseInner
Anti−Squeal Shim
Outer Pad
Anti−Squeal Shim Inner Anti−Squeal Shim Anti−Squeal
Shim
Inner PadAnti−Squeal Spring
Pin Clip
Brake Caliper
Piston Seal
Piston Boot Set Ring DiscPiston Seal
Piston
Boot
Set Ring
Lithium soap base glycol grease
Pad Wear
Indicator Plate BR−24
− BRAKEFRONT BRAKE PAD (4WD)
1629 Author: Date:
1996 TOYOTA T100 (RM449U)
FRONT BRAKE PAD (4WD)
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine BR096−01
R08165
Z04448
R08166
− BRAKEFRONT BRAKE PAD (4WD)
BR−25
1996 TOYOTA T100 (RM449U)
REPLACEMENT
1. REMOVE FRONT WHEEL
2. INSPECT PAD LINING THICKNESS
Check the pad thickness and replace pads if not within specifi-
cation.
Minimum thickness: 1.0 mm (0.039 in.)
3. REMOVE THESE PARTS:
Clip
2 pins
Anti−rattle spring
2 pads
4 anti−squeal shims
NOTICE:
The anti−rattle spring 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.
4. CHECK DISC THICKNESS AND RUNOUT
(See page BR−36)
5. INSTALL NEW PADS
NOTICE:
When replacing worn pads, the anti−squeal shims must be
replaced together with the pads.
(a) Draw out a small amount of brake fluid from the reservoir.
(b) Press in the pistons with a hammer handle or equivalent.
HINT:
Always change the pad on one wheel at a time as there
is a possibility of the opposite piston flying out.
If the piston is difficult to push in, loosen the bleeder plug
and push in the piston while letting some brake fluid es-
cape.
(c) Install the 4 anti−squeal shims to new pads.
HINT:
Apply disc brake grease to the inner anti−squeal shims (See
page BR−24).
(d) Install the 2 pads.
NOTICE:
Do not allow oil or grease on the rubbing face.
6. INSTALL ANTI−RATTLE SPRING AND 2 PINS
7. INSTALL CLIP

Downloaded from www.Manualslib.com manuals search engine BR097−03
Z18924
Z18924
Gasket
Piston
Pad Piston Seal
Torque PlateBleeder Plug
Dust Boot
Sliding Bushing
Brake Caliper
Anti−Squeal Spring
Pad Wear Indicator Plate 1 ton :
0.5 ton :Dust Boot
Dust Boot Anti−Squeal Shim
Bleeder PlugBrake Caliper
Piston Seal
Piston
Torque Plate
Pad
Anti−Squeal Shim Pad Support Plate Boot
Set Ring
Boot
Pad Support PlateGasket
Sliding Pin
Inner Anti Squeal Shim
Pad Wear
Indicator Plate
Non−reusable part
Lithium soap base glycol grease
Disc brake grease

N·m (kgf·cm, ft·lbf)
: Specified torque
39 (400, 29)
36 (370, 27)
15 (155, 11)
15 (155, 11)
BR−26
− BRAKEFRONT BRAKE CALIPER (2WD)
1631 Author: Date:
1996 TOYOTA T100 (RM449U)
FRONT BRAKE CALIPER (2WD)
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine BR098−03
R04699
− BRAKEFRONT BRAKE CALIPER (2WD)
BR−27
1996 TOYOTA T100 (RM449U)
REMOVAL
1. DISCONNECT FLEXIBLE HOSE
(a) Remove the union bolt and disconnect the flexible hose.
Torque: 15 N·m (155 kgf·cm, 11 ft·lbf)
NOTICE:
At the time of installation, please refer to the following item.
For correct brake hose routing, ensure that the hose hangs
down before installing hose to caliper.
(b) Use a container to catch the brake fluid.
2. REMOVE CALIPER FROM TORQUE PLATE
Remove the 2 installation bolts and caliper.
Torque:
1 ton: 39 N·m (400 kgf·cm, 29 ft·lbf)
Torque:
0.5 ton: 36 N·m (370 kgf·cm, 27 ft·lbf)
3. REMOVE THESE PARTS:
1 ton:
2 anti−squeal springs
2 brake pads with anti−squeal shims
4 pads support plates