1996 TOYOTA T100 brakes

Downloaded from www.Manualslib.com manuals search engine − MAINTENANCEINSIDE VEHICLE
MA−3
38 Author: Date:
1996 TOYOTA T100 (RM449U)
13. ACCELERATOR PEDAL
Check the pedal for smooth operation and uneven pedal effort or catching.
14. CLUTCH PEDAL
(See page CL−2)
(a) Check the pedal for smooth operation.
(b) Check that the pedal has the proper freeplay.
15. BRAKE PEDAL
(See page BR−6)
(a) Check the pedal for smooth operation.
(b) Check that the pedal has the proper reserve distance and freeplay.
(c) Check the brake booster function.
16. BRAKES
At a safe place, check that the brakes do not pull to one side when applied.
17. PARKING BRAKE
(See page BR−8)
(a) Check that the lever has the proper travel.
(b) On a safe incline, check that the vehicle is held securely with only the parking brake applied.
18. AUTOMATIC TRANSMISSION ”PARK” MECHANISM
(a) Check the lock release button of the selector lever for proper and smooth operation.
(b) On a safe incline, check that the vehicle is held securely with the selector lever in ”P” position and all
brakes released.

Downloaded from www.Manualslib.com manuals search engine MA0568
B02099
B02100
− MAINTENANCECHASSIS
MA−13
48 Author: Date:
1996 TOYOTA T100 (RM449U)
12. TIGHTEN BOLTS AND NUTS ON CHASSIS AND BODY
(a) Tighten these parts:
Seat mounting bolts
Torque:
37 N·m (375 kgf·cm, 27 ft·lbf)

2WD:
Strut bar bracket−to−frame mounting bolts
Torque: 52 N·m (530 kgf·cm, 38 ft·lbf)
Leaf spring U−bolt mounting nuts
Torque: 133 N·m (1,350 kgf·cm, 98 ft·lbf )
(b) Under Severe Conditions:
In addition to the above maintenance items, check for
loose or missing bolts and nuts on the following.
Steering system
Drive train
Suspension system
Fuel tank mounts
Engine mounts, etc.
13. FINAL INSPECTION
(a) Check operation of body parts:
Hood:
Auxiliary catch operates properly
Hood locks securely when closed
Doors:
Door locks operate properly
Doors close properly
Seats:
Seat adjusts easily and locks securely in any
positions
Seat backs lock securely at any angle
Fold−down seat backs lock securely
(b) Road test:
Engine and chassis parts do not have abnormal
noises.
Vehicle does not wander or pull to one side.
Brakes work properly and do not drag.

Downloaded from www.Manualslib.com manuals search engine D09979
DI−316
− DIAGNOSTICSAUTOMATIC TRANSMISSION
1996 TOYOTA T100 (RM449U)
Stop Light Switch Circuit
CIRCUIT DESCRIPTION
The purpose of this circuit is to prevent the engine from stalling, while driving in lock−up condition, when
brakes are suddenly applied.
When the brake pedal is operated, this switch sends a signals to the ECM. Then the ECM cancels operation
of the lock−up clutch while braking is in progress.
WIRING DIAGRAM
DI98I−01

Downloaded from www.Manualslib.com manuals search engine − BRAKETROUBLESHOOTING
BR−3
1608 Author: Date:
1996 TOYOTA T100 (RM449U) Hard pedal but brake inefficient
1. Fluid leaks for brake system
2. Air in brake system
3. Pad or lining (Worn)
4. Pad or lining (Cracked or distorted)
5. Rear brake shoe clearance (Out of adjustment)
6. Pad or lining (Oily)
7. Pad or lining (Glazed)
8. Disk (Scored)
9. Booster push rod (Out of adjustment)
10. Vacuum leaks for booster systemDI−362
BR−4
BR−26
BR−33
BR−39
BR−44
BR−26
BR−33
BR−39
BR−44
BR−39
BR−44
BR−26
BR−33
BR−39
BR−44
BR−26
BR−33
BR−39
BR−44
BR−26
BR−33
BR−20
BR−17
Noise from brakes
1. Pad or lining (Cracked or distorted)
2. Installation bolt (Loose)
3. Disk (Scored)
4. Pad support plate (Loose)
5. Sliding pin (Worn)
6. Pad or lining (Dirty)
7. Pad or lining (Glazed)
8. Anchor or return spring (Faulty)
9. Anti−squeal shim (Damaged)
10. Shoe hold−down spring (Damaged)BR−26
BR−33
BR−39
BR−44
BR−26
BR−33
BR−26
BR−33
BR−26
BR−33
BR−39
BR−44
BR−26
BR−33
BR−39
BR−44
BR−39
BR−44
BR−26
BR−33
BR−39
BR−44

Downloaded from www.Manualslib.com manuals search engine BR0080
BR08S−02
BR0246
R12820
BR−8
− BRAKEPARKING BRAKE LEVER
1613 Author: Date:
1996 TOYOTA T100 (RM449U)
PARKING BRAKE LEVER
ON−VEHICLE INSPECTION
1. CHECK PARKING BRAKE LEVER TRAVEL
Pull the parking brake lever all the way up, and count the num-
ber of clicks.
Parking brake lever travel at 196 N (20 kgf, 44.1 lbf):
11 − 17 clicks
2. 2WD:
IF NECESSARY, ADJUST PARKING BRAKE
HINT:
Before adjusting the parking brake, make sure that the rear
brake shoe clearance has been adjusted.
(a) Tighten the adjusting nut until the travel is correct.
Then tighten the lock nut.
(b) After adjusting the parking brake, confirm that the rear
brakes are not dragging.
3. 4WD:
IF NECESSARY, ADJUST PARKING BRAKE
HINT:
Before adjusting the parking brake, make sure that the rear
brake shoe clearance has been adjusted.
(a) Tighten 1 of the adjusting nuts of the intermediate lever
while loosening the other one until the travel is correct.
Tighten the 2 adjusting nuts.
(b) After adjusting the parking brake, confirm that the bell-
crank stopper screw comes into contact with the backing
plate.

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

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 BR3278
R09580
Z11334
Z03643
− BRAKELOAD SENSING PROPORTIONING AND BY−PASS
VALVE (LSP & BV)BR−51
1656 Author: Date:
1996 TOYOTA T100 (RM449U)
4. IF NECESSARY, ADJUST FLUID PRESSURE
(a) Loosen the lock nut.
(b) Adjust the length of the No.2 shackle.
Low pressure: Lengthen A
High pressure: Shorten A
Initial set: 120 mm (4.72 in.)
Adjustment range: 114 − 126 mm (4.49 − 4.96 in.)
HINT:
One turn of the nut changes the fluid pressure as shown in the
following specification.
7.5 kPa (0.77 kgf/cm, 11 psi)
(c) Torque the lock nut.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(d) If the pressure cannot be adjusted by the No.2 shackle,
raise or lower the valve body. (2WD shown, for 4WD refer
to component illustration on next page.)
Low pressure−Lower body
High pressure−Raise body
(e) Torque the nuts.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
(f) Adjust the length of the No.2 shackle again.
If it cannot be adjusted, inspect the valve housing.
5. IF NECESSARY, CHECK VALVE BODY
(a) Assemble the valve body in the uppermost position.
HINT:
When the brakes are applied, the piston will move down about
0.8 mm (0.03 in.). Even at this time, the piston should not make
contact with or move the load sensing spring.
(b) In this position, check the rear brake pressure.
Front brake pressure
kPa (kgf/cm2, psi)
Rear brake pressure
kPa (kgf/cm2, psi)
1,960 (20, 285)1,960 (20, 285)
3,920 (40, 570)2,352 ± 196 (24 ± 2, 342 ± 28.5)
6,860 (70, 997.5)2,940 ± 343 (30 ± 3.5, 427.5 ± 50)
If the measured value is not within the standard, replace the
valve body.