1996 TOYOTA T100 check engine

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 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 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 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.

Downloaded from www.Manualslib.com manuals search engine BR09G−01
BR0251
BR3183
R08168
BR−36
− BRAKEFRONT BRAKE CALIPER (4WD)
1996 TOYOTA T100 (RM449U)
INSPECTION
1. MEASURE PAD LINING THICKNESS
Using a ruler, measure the pad lining thickness.
Standard thickness: 9.5 mm (0.374 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 front axle hub (See page SA−23).
(b) Install the new axle hub with disc and adjust the front
bearing preload (See page SA−25).

Downloaded from www.Manualslib.com manuals search engine BR09I−01
BR−38
− BRAKEFRONT BRAKE CALIPER (4WD)
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.

Downloaded from www.Manualslib.com manuals search engine BR09K−01
R08164
BR3096
R04711
SST
R04712
SST
R04713
SST BR−40
− BRAKEREAR DRUM BRAKE (2WD)
1996 TOYOTA T100 (RM449U)
REMOVAL
1. INSPECT SHOE LINING THICKNESS
Remove the inspection hole plug, and check the shoe lining
thickness through the hole.
If less than minimum, replace the shoes.
Minimum thickness: 1.0 mm (0.039 in.)
2. REMOVE REAR WHEEL
3. REMOVE BRAKE DRUM
HINT:
If the brake drum cannot be removed easily, do the following
steps.
(a) Remove the adjusting hole plug in the backing plate.
(b) Insert a screwdriver through the hole in the backing plate,
and hold the automatic adjusting lever away from the ad-
justing bolt.
(c) Using another screwdriver, reduce the brake shoe adjust-
ment by turning the adjusting bolt.
4. REMOVE FRONT SHOE
(a) Using SST, disconnect the return spring.
SST 09703−30010
(b) Using SST, remove the shoe hold−down spring, cups and
pin.
SST 09718−00010
(c) Disconnect the anchor spring from the front shoe and re-
move the front shoe.
(d) Remove the anchor spring from the rear shoe.
5. REMOVE ADJUSTER AND REAR SHOE
(a) Using SST, remove the shoe hold−down spring, cups and
pin.
SST 09718−00010
(b) Remove the adjusting lever spring.

Downloaded from www.Manualslib.com manuals search engine BR09M−01
R04724
BR0080
R04725
− BRAKEREAR DRUM BRAKE (2WD)
BR−43
1996 TOYOTA T100 (RM449U)
INSTALLATION
Installation is in the reverse order of removal (See page
BR−40).
NOTICE:
Apply lithium soap base glycol grease and high tempera-
ture grease to the parts indicated by the arrows (See page
BR−39).
1. CHECK OPERATION OF AUTOMATIC ADJUSTER
MECHANISM
(a) Move the parking brake lever of the rear shoe back and
forth, as shown. Check that the adjusting bolt turns.
If the adjuster does not turn, check for incorrect installation of
the rear brakes.
(b) Adjust the adjuster length to the shortest possible
amount.
(c) Install the drum.
(d) Pull the parking brake lever all the way up until a clicking
sound can no longer be heard.
2. CHECK CLEARANCE BETWEEN BRAKE SHOES AND
DRUM
(a) Remove the drum.
(b) Measure the brake drum inside diameter.
(c) Measure the distance between brake shoes. Check that
the difference between the diameters is the correct shoe
clearance.
Shoe clearance: 0.6 mm (0.024 in.)
If incorrect, check the parking brake system.
3. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND
BLEED BRAKE SYSTEM (See Page BR−4)
4. CHECK FOR LEAKS