1996 TOYOTA TERCEL torque

BR0786
BR0RC-06
BR5045
BR-8
- BRAKEPARKING BRAKE LEVER
882 Author
: Date
:
1996 TERCEL (RM440U)
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):
5 - 8 clicks
2. IF NECESSARY, ADJUST PARKING BRAKE
HINT:
Before adjusting the parking brake, make sure that the rear
brake shoe clearance has been adjusted.
For shoe clearance adjustment, see step 2 on page BR-33.
(a) Remove the console box.
(b) Loosen the lock nut and turn the adjusting nut until the le-
ver travel is correct.
(c) Tighten the lock nut.
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
(d) Install the console box.

BR0RE-01
BR5042
SST
BR5041
BR-10
- BRAKEBRAKE MASTER CYLINDER
1996 TERCEL (RM440U)
REMOVAL
1. REMOVE AIR CLEANER ASSEMBLY
2. DISCONNECT LEVEL WARNING SWITCH CONNEC-
TOR
3. DRAW OUT FLUID WITH SYRINGE
NOTICE:
Do not let brake fluid remain on a painted surface. Wash it
off immediately.
4. DISCONNECT BRAKE LINES
Using SST, disconnect the brake lines from the master cylinder.
SST 09751-3601 1
Torque: 15 N´m (155 kgf´cm, 11 ft´lbf)
5. REMOVE MASTER CYLINDER
(a) w/o ABS:
Remove the 2 mounting nuts, clamp and pull out the mas-
ter cylinder and gasket.
Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)
(b) w/ ABS:
Remove the 2 mounting nuts, 2-way and pull out the
master cylinder and gasket.
Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)

BR0RF-06
BR5036
Soft Jaws
BR5037
Soft Jaws
R12236
A
- BRAKEBRAKE MASTER CYLINDER
BR-1 1
1996 TERCEL (RM440U)
DISASSEMBLY
1. REMOVE RESERVOIR
(a) Remove the set screw and pull out the reservoir.
Torque: 1.7 N´m (17.5 kgf´cm, 15.2 in.´lbf)
(b) Remove the cap and strainer from the reservoir.
2. REMOVE 2 GROMMETS
3. PLACE CYLINDER IN VISE
4. REMOVE PISTON STOPPER BOLT
Using a screwdriver, push the pistons in all the way and remove
the piston stopper bolt and gasket.
HINT:
Tape the screwdriver tip before use.
Torque: 10 N´m (100 kgf´cm, 7 ft´lbf)
5. REMOVE PISTONS
(a) Push in the piston with a screwdriver and remove the
snap ring with snap ring pliers.
(b) Remove the No.1 piston and spring by hand, pulling
straight out, not at an angle.
NOTICE:

If pulled out and installed at an angle, there is a possi-
bility that the cylinder bore could be damaged.

Be careful not to damage the rubber lips on the pis-
tons.
(c) Place a rag and 2 wooden blocks on the work table and
lightly tap the cylinder flange against the block edges until
the No.2 piston drops out of the cylinder.
HINT:
Make sure the distance (A) from the rag to the top of the blocks
is at least 100 mm (3.94 in.).

BR0RM-04
F03521
SST
Gasket
N00744
SST
BR1728 BR0021
BR-18
- BRAKEBRAKE BOOSTER ASSEMBLY
1996 TERCEL (RM440U)
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: 14 N´m (145 kgf´cm, 10 ft´lbf)
(d) Insert the clevis pin into the clevis and brake pedal, and
install the clip to the clevis pin.
(e) Install the pedal return spring.
(f) Install the No.1 brake line clamp to the body.
(g) Install the No.2 brake line clamp to the body.
2. ADJUST LENGTH OF BOOSTER PUSH ROD
(a) Install the gasket on the master cylinder.
(b) Set SST on the gasket, and lower the pin until its tip slight-
ly touches the piston.
SST 09737-00010
(c) Turn 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
slightly touches the pin head.
HINT:
When loosening the push rod nut, depress the brake pedal
enough so that the push rod sticks out.
3. INSTALL MASTER CYLINDER
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 LEAKS

- BRAKEBRAKE BOOSTER ASSEMBLY
BR-19
1996 TERCEL (RM440U)
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-15)

BR0RO-03
BR4213
BR4214
BR0272
- BRAKEFRONT BRAKE PAD
BR-21
1996 TERCEL (RM440U)
REPLACEMENT
1. REMOVE FRONT WHEEL
Remove the wheel and temporarily fasten the disc with hub
nuts.
2. INSPECT PAD LINING THICKNESS
Check the pad thickness through the caliper inspection hole
and replace the pads if they are not within the specification.
Minimum thickness: 1.0 mm (0.039 in.)
3. REMOVE CALIPER
(a) Remove the 2 installation bolts from the torque plate.
(b) Remove the caliper and suspend it securely.
HINT:
Do not disconnect the flexible hose.
4. REMOVE THESE PARTS:
(a) 2 brake pads
(b) 3 anti-squeal shims
(c) Pad wear indicator plate
(d) 4 pad support plates
NOTICE:
The support plates 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.
5. CHECK DISC THICKNESS AND RUNOUT
(See page BR-26)
6. INSTALL 4 PAD SUPPORT PLATES
7. INSTALL NEW PADS
NOTICE:
When replacing worn pads, the anti-squeal shims and
wear indicator plates must be replaced together with the
pads.
(a) Install a pad wear indicator plate on the inner pad.
(b) Apply disc brake grease to the anti-squeal shims (See
page BR-23).
(c) Install the 2 anti-squeal shims on the outer pad.
(d) Install the anti-squeal shim on the inner pad

N00746
BR-22
- BRAKEFRONT BRAKE PAD
1996 TERCEL (RM440U)
(e) Install inner pad with the pad wear indicator plate facing
upward.
(f) Install outer pad.
NOTICE:
There should be no oil or grease adhering to the friction
surfaces of the pads or the disc.
8. INSTALL CALIPER
(a) Draw out a small amount of brake fluid from the reservoir.
(b) Press in the piston with a hammer handle or an equiva-
lent.
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) Install the caliper.
(d) Install and torque the 2 installation bolts.
Torque: 25 N´m (255 kgf´cm, 18 ft´lbf)
9. INSTALL FRONT WHEEL
10. CHECK THAT FLUID LEVEL IS AT MAX LINE

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.