1996 TOYOTA TERCEL e brake

BR0RP-06
- BRAKEFRONT BRAKE CALIPER
BR-23
897 Author
: Date
:
1996 TERCEL (RM440U)
FRONT BRAKE CALIPER
COMPONENTS

BR0RQ-05
BR4220
BR-24
- BRAKEFRONT BRAKE CALIPER
1996 TERCEL (RM440U)
REMOVAL
1. DISCONNECT FLEXIBLE HOSE
(a) Remove the union bolt and 2 gaskets from the caliper,
then disconnect the flexible hose from the caliper.
Torque: 30 N´m (310 kgf´cm, 22 ft´lbf)
HINT:
Install the flexible hose lock securely in the lock hole in the cali-
per.
(b) Use a container to catch the brake fluid as it drains out.
2. REMOVE CALIPER
Remove the 2 installation bolts, and caliper.
Torque: 25 N´m (255 kgf´cm, 18 ft´lbf)
3. REMOVE THESE PARTS:
(a) 2 brake pads with anti-squeal shims.
(b) 4 pad support plates.

BR0RR-03
N00747 BR3964 BR3965
BR3966
BR3968
BR3969
- BRAKEFRONT BRAKE CALIPER
BR-25
1996 TERCEL (RM440U)
DISASSEMBLY
1. REMOVE THESE PARTS:
(a) 2 sliding bushings.
(b) 4 dust boots.
2. REMOVE CYLINDER BOOT SET RING AND CYL-
INDER BOOT
Using a screwdriver, remove the cylinder boot set ring and cylin-
der boot from the caliper.
3. REMOVE PISTON
(a) Place a piece of cloth or similar, between the piston and
the 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
Using a screwdriver, remove the piston seal from the cylinder.

BR0RS-07
BR4362
BR4237
BR4238
BR4221
BR-26
- BRAKEFRONT BRAKE CALIPER
1996 TERCEL (RM440U)
INSPECTION
1. MEASURE PAD LINING THICKNESS
Using a ruler, measure the pad lining thickness.
Standard thickness: 10.0 mm (0.394 in.)
Minimum thickness: 1.0 mm (0.039 in.)
Replace the pad if the pad's thickness is at the minimum thick-
ness or less, or if the pad has severe and uneven wear.
2. MEASURE DISC THICKNESS
Using a micrometer, measure the disc thickness.
Standard thickness: 18.0 mm (0.709 in.)
Minimum thickness: 17.0 mm (0.689 in.)
Replace the disc if the disc's thickness is at the minimum thick-
ness or less. Replace the disc or grind it on a lathe if it is badly
scored or worn unevenly.
3. MEASURE DISC RUNOUT
Using a dial indicator, measure disc runout 10 mm (0.39 in.)
away from the outer.
Maximum disc runout: 0.07 mm (0.0028 in.)
If the disc's runout is the maximum value or greater, check the
bearing play is in the axial direction and check the axle hub run-
out (See page SA-10). If the bearing play and axle hub runout
are not abnormal, adjust the disc runout or grind it on a ºOn-carº
brake late.
4. IF NECESSARY, ADJUST DISC RUNOUT
(a) Remove the torque plate from the knuckle.
(b) Remove the hub nuts and the disc. Reinstall the disc in
the position turned 1/4 from its original position on the
hub. Install and torque the hub nuts.
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
Remeasure the disc runout. Make a note of the runout and the
disc's position on the hub.
(c) Repeat (b) until the disc has been installed on the 2 re-
maining hub positions.
(d) If the minimum runout recorded in (b) and (c) is less than
0.07 mm (0.0028 in.), install the disc in that position.
(e) If the minimum runout recorded in (b) and (c) is greater
than 0.07 mm (0.0028 in.), replace the disc and repeat
step 3.
(f) Install the torque plate and fighten the 2 bolts.
Torque: 88 N´m (900 kgf´cm, 65 ft´lbf)

BR0RT-04
- BRAKEFRONT BRAKE CALIPER
BR-27
1996 TERCEL (RM440U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page BR-25).
NOTICE:
Apply lithium soap base glycol grease to the parts indicated by arrows (See page BR-23).

BR0RU-04
BR-28
- BRAKEFRONT BRAKE CALIPER
1996 TERCEL (RM440U)
INSTALLATION
Installation is in the reverse order of removal (See page BR-24).
1. AFTER INSTALLATION, FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE
SYSTEM (See page BR-4)
2. CHECK FOR LEAKS

BR0RV-04
- BRAKEREAR DRUM BRAKE
BR-29
903 Author
: Date
:
1996 TERCEL (RM440U)
REAR DRUM BRAKE
COMPONENTS

BR4239
BR0RW-03
BR4240
N00750 BR0405 BR0406
BR4241
SST BR-30
- BRAKEREAR DRUM BRAKE
1996 TERCEL (RM440U)
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 (See page SA-39)
HINT:
If the brake drum cannot be removed easily, do the following
steps.
(a) Insert a screwdriver through the hole in the backing plate,
and hold the automatic adjusting lever away from the ad-
juster.
(b) Using another screwdriver, reduce the brake shoe adjust-
er by turning the adjusting wheel.
4. REMOVE FRONT SHOE
(a) Using, remove the return spring and calmp.
(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 REAR SHOE
(a) Using SST, remove the shoe hold-down spring, cups and
pin.
SST 09718-00010
(b) Using pliers, remove the adjusting lever spring.
(c) Remove the adjuster.