1996 TOYOTA T100 torque

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 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 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

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.

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)

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