Page 1665 of 2062

Downloaded from www.Manualslib.com manuals search engine BR099−02
BR3384
BR3079
BR0168
BR3080
BR−28
− BRAKEFRONT BRAKE CALIPER (2WD)
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. 1 ton:
REMOVE CALIPER SLIDING BUSHINGS AND DUST
BOOTS
(a) Remove the sliding bushings.
HINT:
At the time of reassembly, please refer to the following item.
Ensure that the boots are secured firmly to the caliper grooves.
(b) Using a screwdriver and a hammer, remove the dust
boots.
HINT:
At the time of reassembly, please refer to the following item.
Use 2 socket wrenches and a vise, press in new dust boots.
2. REMOVE CYLINDER BOOT SET RING (1 ton) AND
CYLINDER BOOT
Using a screwdriver, remove the cylinder boot set ring (1 ton)
and cylinder boot.
3. REMOVE PISTON FROM CYLINDER
(a) Put a piece of cloth or an equivalent between the piston
and 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.
4. REMOVE PISTON SEAL FROM BRAKE CYLINDER
Using a screwdriver, remove the piston seal.
Page 1666 of 2062
Downloaded from www.Manualslib.com manuals search engine − BRAKEFRONT BRAKE CALIPER (2WD)
BR−29
1996 TOYOTA T100 (RM449U)
5. 0.5 ton:
REMOVE SLIDING PINS AND DUST BOOTS
(a) Remove the 2 sliding pins from the torque plate.
(b) Using a screwdriver and hammer, tap out the 2 dust
boots.
HINT:
At the time of reassembly, please refer to the following item.
Using a 19 mm socket and hammer, 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.
Page 1667 of 2062

Downloaded from www.Manualslib.com manuals search engine BR09A−01
BR0251
R04701
R04702
BR0173
BR−30
− BRAKEFRONT BRAKE CALIPER (2WD)
1996 TOYOTA T100 (RM449U)
INSPECTION
1. MEASURE PAD LINING THICKNESS
Using a ruler, measure the pad lining thickness.
Standard thickness:
1 ton: 9.5 mm (0.374 in.)
Standard thickness:
0.5 ton: 11.0 mm (0.433 in.)
Minimum thickness:
1.0 mm (0.039 in.)
Replace the pad if the thickness is less than the minimum (the
1.0 mm slit is no longer visible), or if it shows signs of uneven
wear.
2. MEASURE DISC THICKNESS
Using a micrometer, measure the disc thickness.
Standard thickness: 25.0 mm (0.984 in.)
Minimum thickness: 23.0 mm (0.906 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 10 mm (0.39 in.)
from the outside edge of the disc.
Maximum disc runout: 0.07 mm (0.0028 in.)
If the runout is greater than the maximum, replace the disc or
grind it on a ”On−Car” brake lathe.
HINT:
Before measuring the runout, check that the front hub bearing
play is within specification.
4. IF NECESSARY, REPLACE DISC
(a) Remove the torque plate from the knuckle.
(b) Remove the axle hub (See page SA−16).
(c) Remove the disc from the axle hub.
(d) Install a new disc. Torque the bolts.
Torque: 64 N·m (650 kgf·cm, 47 ft·lbf)
(e) Install the axle hub and adjust the front bearing preload
(See page SA−19).
(f) Install the torque plate onto the knuckle.
Torque: 108 N·m (1,100 kgf·cm, 80 ft·lbf)
Page 1668 of 2062
Downloaded from www.Manualslib.com manuals search engine BR09B−01
− BRAKEFRONT BRAKE CALIPER (2WD)
BR−31
1996 TOYOTA T100 (RM449U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page BR−28).
NOTICE:
Apply lithium soap base glycol grease to the parts indicated by the arrows (See page BR−26).
Page 1669 of 2062
Downloaded from www.Manualslib.com manuals search engine BR09C−01
BR−32
− BRAKEFRONT BRAKE CALIPER (2WD)
1996 TOYOTA T100 (RM449U)
INSTALLATION
Installation is in the reverse order of removal (See page BR−34).
1. AFTER INSTALLATION, FILL BRAKE RESERVOIR BRAKE FLUID AND BLEED BRAKE SYSTEM
(See page BR−4)
2. CHECK FOR LEAKS.
Page 1670 of 2062
Downloaded from www.Manualslib.com manuals search engine BR09D−02
Z18922Z18922
Inner
Boot Disc
Piston
Set RingPin
Piston Seal Indicator Plate
Anti−Squeal Shim Inner Anti−Squeal Shim Anti−Rattle Spring
Anti−Squeal Shim
Clip
Set Ring Boot
Piston Piston SealAnti−Squeal
ShimBrake Caliper
Inner Pad
Outer Pad
Pad Wear
Lithium soap base glycol grease
Disc brake grease
N·m (kgf·cm, ft·lbf)
15 (155, 11)
123 (1,250, 90)
: Specified torque
− BRAKEFRONT BRAKE CALIPER (4WD)
BR−33
1638 Author: Date:
1996 TOYOTA T100 (RM449U)
FRONT BRAKE CALIPER (4WD)
COMPONENTS
Page 1671 of 2062
Downloaded from www.Manualslib.com manuals search engine BR09E−01
R08172
SST
BR0961
BR−34
− BRAKEFRONT BRAKE CALIPER (4WD)
1996 TOYOTA T100 (RM449U)
REMOVAL
1. REMOVE FRONT WHEEL
2. DISCONNECT BRAKE LINE
Using SST, disconnect the brake line.
Use a container to catch the brake fluid.
SST 09751−36011
Torque: 15 N·m (155 kgf·cm, 11 ft·lbf)
3. REMOVE CALIPER
Remove the 2 mounting bolts and remove the caliper.
Torque: 123 N·m (1,250 kgf·cm, 90 ft·lbf)
4. REMOVE THESE PARTS:
Clip
2 pins
Anti−rattle spring
2 pads
4 anti−squeal shims
Page 1672 of 2062
Downloaded from www.Manualslib.com manuals search engine BR09F−01
BR2008
BR0212
170 mm
(6.70 in.)50 mm
(1.97 in.)
16mm
(0.63 in.)
BR0213
BR2009
− BRAKEFRONT BRAKE CALIPER (4WD)
BR−35
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. REMOVE CYLINDER BOOT SET RINGS AND BOOTS
Using a screwdriver, remove the 4 cylinder boot set rings and
4 boots.
2. REMOVE PISTONS FROM CYLINDER
(a) Prepare the wooden plate to hold the pistons.
(b) Place the plate between the pistons and insert a pad at
one side.
(c) Use compressed air to remove the pistons alternately
from the cylinder.
CAUTION:
Do not place your fingers in front of the pistons when using
compressed air.
3. REMOVE PISTON SEALS
Using a screwdriver, remove the 4 seals from the cylinder.