1996 TOYOTA T100 brake light

Downloaded from www.Manualslib.com manuals search engine BR09Q−01
BR0122
C
A
BAdjusting Bolt
BR0973
Z03640
Z03659
− BRAKEREAR DRUM BRAKE (4WD)
BR−49
1996 TOYOTA T100 (RM449U)
INSTALLATION
Installation is in the reverse order of removal (See page
BR−45).
NOTICE:
Apply lithium soap base glycol grease and high tempera-
ture grease to the parts indicated by the arrows (See page
BR−44).
1. ADJUST BELLCRANK
(a) Lightly pull the bellcrank in direction A until there is no
slack at part B.
(b) In this condition, turn the adjusting bolt so that dimension
C will be 0.4 − 0.8 mm (0.016 − 0.031 in.).
(c) Lock the adjusting bolt with the lock nut.
(d) Connect the parking brake cable to the parking brake bell-
crank and install the clip.
(e) Install the tension spring.
2. CHECK OPERATION OF AUTOMATIC ADJUSTING
MECHANISM
(a) Move the parking brake lever of the front shoe back and
forth. Check that the adjuster turns.
If the adjuster does not turn, check for incorrect installation of
the rear brakes.
(b) Adjust the adjuster length as short as possible.
(c) Install the brake drum.
(d) Pull the parking brake lever all the way up until a clicking
sound can no longer be heard.
3. CHECK CLEARANCE BETWEEN BRAKE SHOES AND
DRUM (See page BR−43)
Shoe clearance: 0.6 mm (0.024 in.)
4. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND
BLEED BRAKE SYSTEM (See Page BR−4)
5. CHECK FOR LEAKS

Downloaded from www.Manualslib.com manuals search engine BR09X−01
Z11332
SST
Z11333
A
BR0218
BR0061
SST
− BRAKELOAD SENSING PROPORTIONING AND BY−PASS
VALVE (LSP & BV)BR−57
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. INSTALL LSP & BV ASSEMBLY TO FRAME
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
2. CONNECT BRAKE LINE
Using SST, connect the brake lines.
Torque: 15 N·m (155 kgf·cm, 11 ft·lbf)
SST 09751−36011
3. CONNECT SHACKLE NO.2 BRACKET
(a) Install the shackle No.2 to the load sensing spring.
(b) Set dimension A and torque the lock nut.
Initial set: 120 mm (4.72 in.)
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(c) Connect the shackle No.2 to the shackle bracket.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
(d) Install a new cotter pin.
4. SET REAR AXLE LOAD
(See page BR−50)
5. SET VALVE BODY
(a) When pulling down the load sensing spring, check that
the valve piston moves down smoothly.
(b) Position the valve body so that the valve piston lightly
contacts with the load sensing spring.
(c) Tighten the valve body mounting nuts.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
6. BLEED BRAKE LINE (See page BR−4)
7. CHECK AND ADJUST LSP & BV FLUID PRESSURE
(See page BR−50)
8. APPLY SEALANT TO SHACKLE No.2
Apply sealant to the top portion of the shackle No.2 bolt threads
not to lose the upper lock nut.
Sealant:
Part No. 08833−00070, THREE BOND 1324 or equiva-
lent

Downloaded from www.Manualslib.com manuals search engine BE−4
− BODY ELECTRICALBODY ELECTRICAL SYSTEM
1996 TOYOTA T100 (RM449U) Headlight does not go out with light control SW in OFF.
1. Headlight Control Relay
2. Light Control Switch
3. Wire HarnessBE−17
BE−17
−
Taillight does not light up with light control SW in TAIL.
1. Taillight Control Relay
2. Light Control Switch
3. Wire HarnessBE−17
BE−17
−
Taillight does not go out with light control SW in OFF.
1. Taillight Control Relay
2. Light Control Switch
3. Wire HarnessBE−17
BE−17
−
Headlight do not light up with engine running, parking brake SW
and light control SW in OFF.
1. ECU−B Fuse (Junction Block No.1)
2. GAUGE Fuse (Junction Block No.1)
3. DRL Fuse (Junction Block No.1)
4. D.R.L. Relay
5. D.R.L. No.4 Relay
6. D.R.L. Resistor
7. Wire Harness
8. Generator L Terminal
9. Parking Brake SwitchBE−14
BE−14
BE−14
BE−17
BE−17
BE−17
−
−
BE−38
”Light−on warning system” does not operate.
1. Integration Relay
2. DOME Fuse (Relay Block)
3. GAUGE Fuse (Junction Block No.1)
4. Door Courtesy Switch
5. Wire HarnessBE−17
BE−14
BE−14
BE−25
−
TURN SIGNAL AND HAZARD WARNING SYSTEM
SymptomSuspect AreaSee page
”Hazard” and ”Turn” do not light up
1. Hazard Warning Switch
2. Turn Signal Flasher
3. Wire HarnessBE−23
BE−23
−
The flashing frequency is abnormal
1. Bulb
2. Turn Signal Switch
3. Wire Harness−
BE−23
−
Hazard warning light does not light up
(Turn signal is normal)1. HAZ−HORN Fuse (Relay Block)
2. Wire HarnessBE−22
−
Hazard warning light does not light up in one direction1. Hazard Warning Switch
2. Wire HarnessBE−23
−
*1 Turn signal does not light up
1. Ignition Switch
2. TURN Fuse (Junction Block No.1)
3. Turn Signal Switch
4. Wire HarnessBE−12
BE−22
BE−23
−
*2 Turn signal does not light up
1. TURN Fuse (Junction Block No.1)
2. Turn Signal Switch
3. Wire HarnessBE−22
BE−23
−
Turn signal does not light up in one direction1. Turn Signal Switch
2. Wire HarnessBE−23
−
Only one bulb does not light up1. Bulb
2. Wire Harness−
−
*1: Combination Meter, Wiper and Washer do not operate.
*
2: Combination Meter, Wiper and Washer are normal.

Downloaded from www.Manualslib.com manuals search engine − BODY ELECTRICALBODY ELECTRICAL SYSTEM
BE−7
1996 TOYOTA T100 (RM449U) A/T Oil temperature warning indicator light does not light up
1. Bulb
2. Combination Meter Wiring Circuit
3. A/T Oil Temperature Sensor
4. Wire Harness−
BE−36
BE−38
−
SRS warning light does not light up
1. Bulb
2. Combination Meter Wiring Circuit
3. Center Airbag Sensor Assembly
4. Wire Harness−
BE−36
DI−372
−
Malfunction indicator does not light up
1. Bulb
2. ECM
3. Wire Harness−
−
−
−
Seat belt warning light does not light up
1. Bulb
2. Integration Relay
3. Wiring Harness−
−
−
Discharge warning light does not light up
1. IGN Fuse (Junction Block No.1)
2. Bulb
3. Wire Harness
4. Generator−
−
−
−
Brake warning light does not light up
1. Bulb
2. Combination Meter Wiring Circuit
3. Parking Brake Switch
4. Brake Fluid Level Warning Switch−
BE−36
BE−38
BE−38
COMBINATION METER
Indicator Lights:
SymptomSuspect AreaSee page
O/D OFF indicator light does not light up
1. Bulb
2. Combination Meter Wiring Circuit
3. O/D OFF Switch
4. Wire Harness−
BE−36
DI−311
−
High beam indicator light does not light up
1. Bulb
2. Combination Meter Wiring Circuit
3. Wire Harness
4. Headlight System−
BE−36
−
BE−2
Turn indicator light does not light up
1. Bulb
2. Combination Meter Wiring Circuit
3. Wire Harness
4. Turn Signal and Hazard Warning System−
BE−36
−
BE−2
Shift indicator lights do not light up (ALL)
1. Bulb
2. Combination Meter Wiring Circuit
3. PNP Switch
4. Wire Harness−
BE−36
DI−306
−
Shift indicator lights do not light up (L, 2, D)
1. Bulb
2. Combination Meter Wiring Circuit
3. PNP Switch
4. Light Control Rheostat
5. Wire Harness−
BE−36
DI−306
BE−38
−
Only one shift indicator does not light up1. Bulb
2. Combination Meter Wiring Circuit−
BE−36

Downloaded from www.Manualslib.com manuals search engine Z10157
From Back Side
17
Z08559
1
2
3
41
2
3
4
− BODY ELECTRICALHEADLIGHT AND TAILLIGHT SYSTEM
BE−19
1996 TOYOTA T100 (RM449U) Tester connection
ConditionSpecified condition
5 − GroundLight control switch OFF or TAILNo continuity
5 − GroundLight control switch HEADContinuity
7 − Ground
16 − GroundHeadlight dimmer switch
Low beamNo continuity
7 − Ground
16 − GroundHeadlight dimmer switch
High beam or FlashContinuity
8 − GroundParking brake switch OFF
(Parking brake lever released)No continuity
8 − GroundParing brake switch ON
(Parking brake lever pulled up)Continuity
12 − GroundConstantContinuity
13 − GroundConstantContinuity
2 − GroundIgnition switch LOCK or ACCNo voltage
2 − GroundIgnition switch ON or STARTBattery positive voltage
6 − GroundConstantBattery positive voltage
11 − GroundEngine StopNo voltage
11 − GroundEngine RunningBattery positive voltage
If circuit is as specified, perform inspections.
8. Connector Connected:
INSPECT DAYTIME RUNNING LIGHT RELAY CIRCUIT
Connect the wire harness side connector to the relay and in-
spect wire harness side connector from the back side, as
shown.
Tester connectionConditionSpecified condition
17 − GroundHeadlight dimmer switch
Low beamNo voltage
17 − GroundHeadlight dimmer switch
High beam or FlashBattery positive voltage
If circuit is as specified, trying replacing the relay with a new
one.
9. INSPECT DAYTIME RUNNING LIGHT RELAY NO.4
CONTINUITY
ConditionTester connectionSpecified condition
Constant3 − 4Continuity
Apply B+ between
terminals 3 and 4.1 − 2Continuity
If continuity is not as specified, replace the relay.

Downloaded from www.Manualslib.com manuals search engine BE03A−03
Z09279
2
1
Z09280
BE−30
− BODY ELECTRICALSTOP LIGHT SYSTEM
1996 TOYOTA T100 (RM449U)
INSPECTION
INSPECT STOP LIGHT SWITCH CONTINUITY
w/o Cruise Control:
Switch positionTester connectionSpecified condition
Switch pin free (Brake
pedal depressed)1 − 2Continuity
Switch pin pushed in
(Brake pedal released)−No continuity
If continuity is not as specified, replace the switch.
w/ Cruise Control:
Switch positionTester connectionSpecified condition
Switch pin free (Brake
pedal depressed)2 − 4Continuity
Switch pin pushed in
(Brake pedal released)1 − 3Continuity
If continuity is not as specified, replace the switch.

Downloaded from www.Manualslib.com manuals search engine N06234
Oil Pressure Gauge
Ignition
Switch
BatteryTest Bulb
(3.4W)
Z09833
w/ TachometerAB
BE4917
Test LED
Battery
BE1217
Ignition
Switch
BatteryWarning Light
BE2570
ONOFF
− BODY ELECTRICALCOMBINATION METER
BE−43
1996 TOYOTA T100 (RM449U)
(c) Ground terminal on the wire harness side connector
through a 3.4 W test bulb.
(d) Turn the ignition ON, check that the bulb lights up and the
receiver gauge needle moves to the high side.
If resistance value is not as specified, replace the receiver
gauge.
16. INSPECT OIL PRESSURE RECEIVER GAUGE RESIS-
TANCE
Measure the resistance between terminals A and B.
Resistance: Approx. 25.0 Ω
If resistance value is not as specified, replace the receiver
gauge.
17. INSPECT OIL PRESSURE SENDER GAUGE OPERA-
TION
(a) Disconnect the connector from the sender gauge.
(b) Apply battery positive voltage to the sender gauge termi-
nal through a test LED.
(c) Check that the bulb does not light when the engine is
stopped.
(d) Check that the LED flashes when the engine is running.
The number of flashes should vary with the engine speed.
If operation is not as specified, replace the sender gauge.
18. INSPECT BRAKE WARNING LIGHT
(a) Disconnect the connectors from the level warning switch
and parking brake switch.
(b) Connect terminals on the wire harness side connector of
the level warning switch connector.
(c) Turn the ignition switch ON, check that the warning light
lights up.
If the warning light does not light up, test the bulb.
19. INSPECT BRAKE FLUID LEVEL WARNING SWITCH
(a) Check that there is no continuity between terminals with
the switch OFF (float up).
(b) Check that there is continuity between terminals with the
switch ON (float down).
If operation is not as specified, replace the switch.

Downloaded from www.Manualslib.com manuals search engine N06136
ON
OFF
BE1217
Warning Light
Ignition
Switch
Battery
N07797
ONOFF
N13155
Warning Light
Ignition
Switch
Battery
N06137
ON
OFF BE−44
− BODY ELECTRICALCOMBINATION METER
1996 TOYOTA T100 (RM449U)
20. INSPECT PARKING BRAKE SWITCH
(a) Check that there is continuity between terminals with the
switch ON (switch pin released).
(b) Check that there is no continuity between terminals with
the switch OFF (switch pin pushed in).
If operation is not as specified, replace the switch.
21. INSPECT WASHER LEVEL WARNING LIGHT
(a) Disconnect the connectors from the level warning switch
and parking brake switch.
(b) Connect terminals on the wire harness side connector of
the level warning switch connector.
(c) Remove the CHARGE fuse and turn the ignition switch
ON, check that the warning light come on.
If the warning light does not light up, test the bulb.
22. INSPECT WASHER LEVEL SWITCH
(a) Check that there is no continuity between terminals with
the switch OFF (float up).
(b) Check that there is continuity between terminals with the
switch ON (float down).
If operation is not as specified, replace the switch.
23. INSPECT SEAT BELT WARNING LIGHT
(a) Remove the integration relay from the junction block
No.1.
(b) Ground terminal 9 on the junction block side connector.
(c) Turn the ignition switch ON, check that the warning light
lights up.
If the warning light does not light up, inspect the bulb or wire har-
ness.
24. INSPECT BUCKLE SWITCH CONTINUITY
(a) Check that there is continuity between terminals on the
switch side connector with the switch ON (belt unfas-
tened).
(b) Check that there is no continuity between terminals on the
switch side connector with the switch OFF (belt fastened).
If operation is not as specified, replace the seat belt inner.