Brake PDF

BR–1
BRAKE – BRAKE SYSTEM
BRAKE SYSTEM
BR0A9–03
PRECAUTION
Care must be taken to replace each part properly as it could affect the performance of the brake
system and result in a driving hazard. Replace the parts with parts having the same part number
or equivalent.
It is very important to keep parts and the area clean when repairing the brake system.
If the vehicle is equipped with a mobile communication system, refer to the precautions in the
IN section.
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2003 TOYOTA TUNDRA (RM956U)
Author: Date: 1876

BR–2
BRAKE – TROUBLESHOOTING
TROUBLESHOOTING
BR08P–05
PROBLEM SYMPTOMS TABLE

Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
Symptom Suspect Area See page
4. Fluid leaks for brake system DI–487
5. Air in brake system DI–487
6. Piston seals (Worn or damaged) BR–26
Low pedal or spongy pedal
7. Rear brake shoe clearance (Out of adjustment) BR–37
8. Master cylinder (Faulty) BR–14
9. Booster push rod (Out of adjustment) BR–23
1. Brake pedal freeplay (Minimum) BR–6

2. Parking brake lever travel (Out of adjustment) BR–13
3. Parking brake pedal travel (Out of adjustment) BR–9
4. Parking brake wire (Sticking)
6. Pad or lining (Cracked or distorted) BR–24
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Brake drag BR–32
7. Piston (Stuck) BR–26
8. Piston (Frozen) BR–26
9. Anchor or return spring (Faulty) BR–32
10.Booster push rod (Out of adjustment) BR–23
11.Vacuum leaks for booster system BR–20
12.Master cylinder (Faulty) BR–14
1. Piston (Stuck) BR–26

2. Pad or lining (Oily) BR–24
BR–32
Brake pull 3. Piston (Frozen) BR–26
4. Disc (Scored) BR–26
BR–32
Author: Date: 1877

BR–3
BRAKE – TROUBLESHOOTING
1. Fluid leaks for brake system DI–487

2. Air in brake system DI–487
3. Pad or lining (Worn) BR–24
BR–32
BR–32
Hard pedal but brake inefficient
6. Pad or lining (Oily) BR–24
BR–32
7. Pad or lining (Glazed) BR–24
BR–32
9. Booster push rod (Out of adjustment) BR–23
10.Vacuum leaks for booster system BR–20
BR–32
2. Installation bolt (Loose) BR–26
4. Pad or lining (Dirty) BR–24
Noise from brakes BR–32
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5. Pad or lining (Glazed) BR–24
BR–32
6. Anchor or return spring (Faulty) BR–32
7. Anti–squeal shim (Damaged) BR–24
8. Shoe hold–down spring (Damaged) BR–32
Author: Date: 1878

BR–4
BRAKE – BRAKE FLUID
BRAKE FLUID BR08Q–02
BLEEDING
HINT:
If any work is done on the brake system or if air is suspected in
the brake lines, bleed the air from the system.
NOTICE:
Do not let brake fluid remain on a painted surface. Wash it
F07756
off immediately.
1. FILL BRAKE RESERVOIR WITH BRAKE FLUID
Check the fluid level in the reservoir after bleeding each wheel.
Add fluid, if necessary.
Fluid: SAE J1703 or FMVSS No. 116 DOT3
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2. BLEED MASTER CYLINDER
HINT:
If the master cylinder was disassembled or if the reservoir be-
comes empty, bleed the air from the master cylinder.
(a) Disconnect the brake lines from the master cylinder.
SST 09023–00100
(b) Slowly depress the brake pedal and hold it.
F07758
(c) Block off the outlet plug with your finger, and release the
brake pedal.
(d) Repeat (b) and (c) 3 or 4 times.
F07759
3. BLEED BRAKE LINE

(a) Connect the vinyl tube to the caliper.
(b) Depress the brake pedal several times, then loosen the
bleeder plug with the pedal held down.
SST 09751–36011
(c) At the point when fluid stops coming out, tighten the
bleeder plug, then release the brake pedal.
(d) Repeat (b) and (c) until all the air in the fluid has been bled
BR3885 out.
Torque: (Bleeder plug) 11 N·m (110 kgf·cm, 8 ft·lbf)
Author: Date: 1879

BR–5
BRAKE – BRAKE FLUID
(e) Repeat the procedure on the previous page to bleed the

air out of brake line for each wheel.
4. CHECK FLUID LEVEL IN RESERVOIR
Check the fluid level and add fluid if necessary.
Fluid: SAE J1703 or FMVSS No. 116 DOT3
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Author: Date: 1880

BR–6
BRAKE – BRAKE PEDAL
BRAKE PEDAL BR107–01
Stop Light Switch ON–VEHICLE INSPECTION

1. CHECK PEDAL HEIGHT
Pedal height from dash panel:
164 – 174 mm (6.46 – 6.85 in.)
2. IF NECESSARY, ADJUST PEDAL HEIGHT
(a) Remove the scuff plate LH, cowl side trim LH, lower finish
panel and No. 2 heater to register duct (See page
BO–72).
(b) Disconnect the connector from the stop light switch.
Push
Rod (c) Loosen the stop light switch lock nut and remove the stop
light switch.
(d) Loosen the push rod lock nut.
(e) Adjust the pedal height by turning the pedal push rod.
(f) Tighten the push rod lock nut.
Pedal Height
Torque: 25 N·m (260 kgf·cm, 19 ft·lbf)
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(g) Install the stop light switch and turn it until it lightly con-
F07754
tacts the pedal stopper.
(h) Connect the connector to the stop light switch.
(i) Push in the brake pedal 5 – 15 mm (0.20 – 0.59 in), turn
the stop light switch to lock the nut in the position where
the stop light goes off.
(j) After installation, push in the brake pedal 5 – 15 mm (0.20
– 0.59 in.), check that stop light lights up.
(k) After adjusting the pedal height, check the pedal free
play.
(l) Install the No. 2 heater to register duct, lower finish panel,
cowl side trim LH and scuff plate LH.
3. CHECK PEDAL FREE PLAY

(a) Stop the engine and depress the brake pedal several
times until there is no more vacuum left in the booster.
Pedal Free Play (b) Push in the pedal by hand until the second point of resis-
tance begins to be felt, then measure the distance as
shown in the illustration.
Pedal free play: 1 – 6 mm (0.04 – 0.24 in.)
If incorrect , check the stop light switch clearance. If the clear-
R00085 ance is OK, then troubleshoot the brake system.
Stop light switch clearance:
0.5 – 2.4 mm (0.020 – 0.094 in.)
HINT:
The free play to the first point of resistance is due to the play
between the clevis and pin. It is 1 – 3 mm (0.04 – 0.12 in.) at the
pedal.
Author: Date: 1881

BR–7
4. CHECK PEDAL RESERVE DISTANCE

Pedal Reserve Distance
Release the parking brake.
With the engine running, depress the pedal and measure the
pedal reserve distance, as shown.
Pedal reserve distance from asphalt sheet at 490 N
(50 kgf, 110.2 lbf): More than 95 mm (3.74 in.)
If the reserve distance is incorrect, troubleshoot the brake sys-
tem.
R00135
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Author: Date: 1882

BR–8
BR108–01
COMPONENTS
A/T:
No. 2 Heater to Register Duct
Lower Finish Panel
Hood Lock Release Lever

Brake Pedal Bracket
Stop Light Switch

M/T:
13 (130, 9)
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13 (130, 9)
Bushing
Pedal Pad
Bushing
Collar
34 (350, 25)
Clip Brake Pedal

Brake Pedal
Lever
Clevis Pin Return Spring
Cushion Plate
Bushing
Cushion Collar Pedal Pad
Collar
Pin Brake Pedal

E–Ring 34 (350, 25)
Brake Pedal
Link
Cowl Side
Trim
Front Door Scuff Plate
N·m (kgf·cm, ft·lbf) : Specified torque

Non–reusable part
Lithium soap base glycol grease F08200
Author: Date: 1883

BR–9
BRAKE – PARKING BRAKE PEDAL
PARKING BRAKE PEDAL BR109–01
ON–VEHICLE INSPECTION
1. CHECK PARKING BRAKE PEDAL TRAVEL
Depress the parking brake pedal all the way and count the num-
ber of clicks.
Parking brake pedal travel at 294 N (30 kgf, 66 lbf):
6 – 9 clicks
F07755
If incorrect, adjust the parking brake.
2. IF NECESSARY, ADJUST PARKING BRAKE PEDAL

TRAVEL
HINT:
Adjusting Before adjusting the parking brake, make sure that the rear
Nut brake shoe clearance has been adjusted. For shoe clearance
adjustment, see step 3 on page BR–37.
(a) Remove the scuff plate LH.
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Lock Nut (b) Remove the cowl side trim LH.
F08199 (c) Remove the lower finish panel.
(d) Remove the No. 2 heater to register duct.
(e) Loosen the lock nut and turn the adjusting nut until the
pedal travel is correct.
(f) Tighten the lock nut.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
(g) Install the removed parts.
Author: Date: 1884

BR–10
BR10A–01
COMPONENTS
Lower Finish Panel
No. 2 Heater to Register Duct
Hood Lock Release Lever
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Parking Brake
Pedal Assembly Parking Brake Wire
Clip
5.4 (55, 48 in.·lbf)
13 (130, 9)
13 (130, 9)
Pedal Pad
Cowl Side Trim
Front Door Scuff Plate

F08201
Author: Date: 1885

BR–11
BR10B–01
REMOVAL
1. REMOVE SCUFF PLATE LH, COWL SIDE TRIM LH, LOWER FINISH PANEL AND NO. 2 HEATER
TO REGISTER DUCT
2. REMOVE PARKING BRAKE PEDAL ASSEMBLY
(a) Disconnect the parking brake switch connector.
(b) Remove the lock nut and adjusting nut from the parking brake wire.
(c) Remove the clip and parking brake wire.
(d) Remove the 4 bolts and parking brake pedal assembly.
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Author: Date: 1886

BR–12
BR10C–01
INSTALLATION
Installation is in the reverse order of removal (See page BR–11).
HINT:
After the installation, check and adjust parking brake pedal travel (See page BR–9).
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Author: Date: 1887

BR–13
BRAKE – PARKING BRAKE LEVER
PARKING BRAKE LEVER BR10D–01
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 lbf):
6 – 14 clicks
BR0080
If incorrect, adjust the parking brake.
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 3 on page BR–37.
(a) Tighten one of the adjusting nuts of the intermediate lever
while loosening the other one until the travel is correct.
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Tighten the 2 adjusting nuts.
F08553 (b) After adjusting the parking brake, confirm that the bell-
crank stopper screw comes into contact with the backing
plate (See page BR–37).
For shoe clearance adjustment, see step 3 on page
Author: Date: 1888

BR–14
BRAKE – BRAKE MASTER CYLINDER
BRAKE MASTER CYLINDER

BR10E–01
COMPONENTS
Level Warning Switch Connector

Brake Master Cylinder
w/ ABS
3–way
15 (155, 11) Brake Booster

15 (155, 11)
15 (155, 11)
Check Valve
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Bracket
15 (155, 11) 4–way
13 (130, 9) 15 (155, 11)
15 (155, 11)
Wire Harness Bracket
Cap
Strainer
Reservoir Set Screw

1.8 (18, 16 in.·lbf)
Reservoir
No. 1 Piston and Spring

No. 2 Piston and Spring
Snap Ring
Grommet
Grommet
Cylinder Body
N·m (kgf·cm, ft·lbf) : Specified torque Gasket

Non–reusable part Piston Stopper Bolt
Lithium soap base glycol grease 10 (100, 7)
F08197
F08196 F08786
Author: Date: 1889

BR–15
BR08U–02
REMOVAL
1. DISCONNECT LEVEL WARNING SWITCH CONNEC-
TOR
2. TAKE OUT FLUID WITH SYRINGE
NOTICE:
Do not let brake fluid remain on a painted surface. Wash it
off immediately.
3. DISCONNECT BRAKE LINES

Using SST, disconnect the 5 or 6 brake lines from the master
cylinder and 3–way or 4–way.
SST 09023–00100
SST
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F07760
4. REMOVE MASTER CYLINDER

(a) w/ ABS:
Remove the 2 nuts, wire harness bracket 3–way and
check valve bracket.
(b) w/o ABS:
Remove the 2 nuts, wire harness bracket 4–way and
check valve bracket.
F07761 Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
(c) Pull out the master cylinder from brake booster.
Author: Date: 1890

BR–16
BR10F–01
DISASSEMBLY
1. REMOVE RESERVOIR
(a) Remove the set screw and pull out the reservoir.
(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.
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F08202
5. REMOVE 2 PISTONS AND SPRINGS

(a) Push in the piston with a screwdriver and remove the
snap ring with snap ring pliers.
HINT:
Tape the screwdriver tip before use.
(b) Remove the No. 1 piston and spring by hand, pulling
straight out, not at an angle.
NOTICE:
F08203 If pulled out and installed at an angle, there is a possi-
bility that the cylinder bore could be damaged.
At the time of reassembly, be careful not to damage
the rubber lips on the pistons.
(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 and spring drop 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.).
A
R12236
Author: Date: 1891

BR–17
BR08W–02
INSPECTION
HINT:
Clean the disassembled parts with compressed air.
1. INSPECT CYLINDER BORE FOR RUST OR SCORING
If necessary, clean or replace the cylinder.
2. INSPECT CYLINDER FOR WEAR OR DAMAGE
If necessary, clean or replace the cylinder.
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Author: Date: 1892

BR–18
BR08X–02
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page BR–16).
NOTICE:
Apply lithium soap base glycol grease to the rubber parts indicated by the arrows (See page
BR–14).
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Author: Date: 1893

BR–19
BR08Y–02
INSTALLATION
HINT:
Before installation, adjust length of brake booster push rod (See page BR–23).
After installation, fill brake reservoir with brake fluid and bleed brake system (See page BR–4).
Check for leaks, check and adjust brake pedal (See page BR–6).
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Author: Date: 1894

BR–20
BRAKE – BRAKE BOOSTER ASSEMBLY
BRAKE BOOSTER ASSEMBLY BR0AK–04
1. OPERATING CHECK
(a) Depress the brake pedal several times with the engine off
and check that there is no change in the pedal reserve
distance.
(b) Depress the brake pedal and start the engine. If the pedal
BR2237
goes down slightly, operation is normal.
GOOD
2. AIR TIGHTNESS CHECK
NO GOOD
(a) Start the engine and stop it after 1 or 2 minutes. Depress
the brake pedal several times slowly.
If the pedal goes down farthest the 1st time, but gradually rises
after the 2nd or 3rd time, the booster is air tight.
(b) Depress the brake pedal while the engine is running, and
3rd stop the engine with the pedal depressed. If there is no
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1st
2nd change in the pedal reserve travel after holding the pedal
BR2238 for 30 seconds, the booster is air tight.
Author: Date: 1895

BR–21
BR10G–01
COMPONENTS
w/ ABS Vacuum Hose

Return Spring
Clevis Pin
Master Cylinder Brake Booster 13 (130, 9)
Stopper Ring
Level Warning
3–way Switch Connector Gasket
Clevis
Clip
15 (155, 11) Gasket
Check Valve Stopper

Bracket 25 (260, 19)
Ring 13 (130, 9)
15 (155, 11)
Brake Booster Bracket
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13 (130, 9) 4–way
15 (155, 11)
15 (155, 11)
15 (155, 11)
15 (155, 11)
13 (130, 9)
Wire Harness Bracket

Non–reusable part F08198
Author: Date: 1896

BR–22
BR10H–01
REMOVAL
1. REMOVE MASTER CYLINDER (See page BR–15)
2. DISCONNECT VACUUM HOSE FROM BRAKE
BOOSTER
3. REMOVE SCUFF PLATE LH, COWL SIDE TRIM LH,
LOWER FINISH PANEL AND NO. 2 HEATER TO REG-
ISTER DUCT (See page BO–72)
4. REMOVE PEDAL RETURN SPRING
5. REMOVE CLIP AND CLEVIS PIN
6. REMOVE BRAKE BOOSTER

(a) Remove the 4 nuts and clevis.
(b) Pull out the brake booster and gasket.
(c) Remove the 2 stopper rings, brake booster bracket and
gasket from the brake booster.
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F08326
Author: Date: 1897

BR–23
BR10I–01
INSTALLATION
1. INSTALL BRAKE BOOSTER
(a) Install a new gasket to the brake booster.
(b) Install the brake booster bracket and 2 stopper rings to
the brake booster.
(c) Install the booster and a new gasket.
(d) Install the clevis to the operating rod.
(e) Install and torque the booster installation nuts.
(f) Install the clevis pin into the clevis and brake pedal, and
install the clip to the clevis pin.
(g) Connect the vacuum hose to the brake booster.
2. INSTALL NO. 2 HEATER TO REGISTER DUCT, LOWER
FINISH PANEL, COWL SIDE TRIM LH AND SCUFF
PLATE (See page BO–79)
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3. ADJUST LENGTH OF BOOSTER PUSH ROD
(a) Set the SST on the master cylinder, and lower the pin until
its tip slightly touches the piston.
SST SST 09737–00011
Master Cylinder
F08555
SST
(b) Turn the SST upside down, and set it on the booster.
SST 09737–00011
(c) Measure the clearance between the booster push rod
and pin head (SST).
Clearance: 0 mm (0 in.)
F05422
(d) Using SST, adjust the booster push rod length until the
push rod lightly touches the pin head.
SST 09737–00020
4. INSTALL MASTER CYLINDER (See page BR–19)
5. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND
BLEED BRAKE SYSTEM (See page BR–4)
6. CHECK FOR FLUID LEAKAGE
7. CHECK AND ADJUST BRAKE PEDAL
SST
F05421 (See page BR–6)
8. DO OPERATIONAL CHECK (See page BR–20)
Author: Date: 1898

BR–24
BRAKE – FRONT BRAKE PAD
FRONT BRAKE PAD

BR10J–01
COMPONENTS
Clip
Inner Pad
Outer Pad
Anti– squeal Shim
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Pin
Anti–rattle
Spring
Inner Anti–squeal
Shim
Disc brake grease

F07750
Author: Date: 1899

BR–25
BRAKE – FRONT BRAKE PAD
BR10K–01
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.)
F07748
3. REMOVE CLIP, 2 PINS AND ANTI–RATTLE SPRING

4. REMOVE 2 PADS AND 4 ANTI–SQUEAL SHIMS
NOTICE:
The anti–rattle spring and clip 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.
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5. CHECK DISC THICKNESS AND RUNOUT
F07749 (See page BR–29)
6. 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 monkey wrench handle or
equivalent.
HINT:
R13537 Tape the monkey wrench handle before use.
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 anti–squeal shims to new pads.
HINT:
Apply disc brake grease to both sides of inner anti–squeal
shims (See page BR–24).
(d) Install new pads.
NOTICE:
Do not allow oil or grease to get on the rubbing face.
7. INSTALL ANTI–RATTLE SPRING AND 2 PINS
8. INSTALL CLIP
9. INSTALL FRONT WHEEL
Torque: 113 N·m (1,150 kgf·cm, 83 ft·lbf)
10. DEPRESS BRAKE PEDAL SEVERAL TIMES
11. CHECK THAT FLUID LEVEL IS AT MAX LINE
Author: Date: 1900

BR–26
BRAKE – FRONT BRAKE CALIPER
FRONT BRAKE CALIPER

BR10L–01
COMPONENTS
Bleeder Plug
11 (110, 8)
15 (155, 11)
123 (1,250, 90)

Piston Seal
Piston
Boot
Set Ring Brake Caliper
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Clip Inner Pad
Outer Pad
Anti–squeal Shim
Anti–rattle
Spring
Pin
Lithium soap base glycol grease Inner Anti–squeal Shim
Disc brake grease
F07751
Author: Date: 1901

BR–27
BR10M–01
REMOVAL
Remove the wheel and temporarily fasten the disc with hub
nuts.
2. DISCONNECT BRAKE LINE

SST
Using SST, disconnect the brake line. Use a container to catch
the brake fluid.
SST 09023–00100
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F07752
3. REMOVE CALIPER
Remove the 2 mounting bolts and caliper.
4. REMOVE CLIP, 2 PINS AND ANTI–RATTLE SPRING
5. REMOVE 2 PADS AND 4 ANTI–SQUEAL SHIMS
NOTICE:
The anti–rattle spring and clip can be used again provided
that they have sufficient rebound, no deformation, cracks
F07753 or wear, and have had all rust, dirt and foreign particles
cleaned off.
Author: Date: 1902

BR–28
BR10N–01
DISASSEMBLY
1. REMOVE CYLINDER BOOT SET RINGS AND BOOTS
Using a screwdriver, remove the 4 cylinder boot set rings and
boots.
R13540
2. REMOVE PISTONS FROM CYLINDER

170 mm 50 mm (a) Prepare the wooden plate to hold the pistons.
(6.70 in.) (1.97 in.)
28 mm
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(1.10 in.)
Z08697
(b) Place the plate between the pistons and insert a pad at
one side.
(c) Use compressed air to remove the pistons alternately
from the cylinder.
CAUTION:
Do not place your fingers in front of the pistons when using
compressed air.
R13541
3. REMOVE PISTON SEALS

Using a screwdriver, remove the 4 piston seals from the cylin-
der.
R13542
Author: Date: 1903

BR–29
BR10O–01
INSPECTION
1. MEASURE PAD LINING THICKNESS
Using a ruler, measure the pad lining thickness.
Standard thickness: 11.5 mm (0.453 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.
R13543
2. MEASURE DISC THICKNESS

Using a micrometer, measure the disc thickness.
Replace the disc if the thickness of the disc is at the minimum
or less. Replace the disc or grind it on a lathe if it is scored or
worn unevenly.
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R13544
3. MEASURE DISC RUNOUT

Using a dial indicator, measure the disc runout at a position 10
mm (0.39 in.) from the outside edge.
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, confirm that the front hub bearing
R13545 play is within the specification (See page SA–9).
4. IF NECESSARY, ADJUST DISC RUNOUT
(a) Remove the hub nuts and disc. Reinstall the disc 1/6 of
a turn round from its original position on the hub. Install
and torque the hub nuts.
(b) Remeasure the disc runout. Make a note of the runout
and the disc’s position on the hub.
(c) Repeat (a) and (b) until the disc has been installed on the
4 remaining hub positions.
If the minimum runout recorded in (a) to (c) is less than the maxi-
mum disc runout, install the disc in that position.
If the minimum runout recorded in (a) to (c) is greater than the
maximum disc runout, replace the disc and repeat step 3.
Author: Date: 1904

BR–30
BR10P–01
REASSEMBLY
NOTICE:
Apply lithium soap base glycol grease and disc brake grease to the parts indicated by the arrows
(See page BR–26).
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Author: Date: 1905

BR–31
BR10Q–01
INSTALLATION
HINT:
Check for leaks.
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Author: Date: 1906

BR–32
BRAKE – REAR DRUM BRAKE
REAR DRUM BRAKE

BR085–03
COMPONENTS
Pin Parking Brake Bellcrank
Tension Spring
Piston
Pin Bleeder Plug Adjuster:
Bellcrank Bracket 11 (110, 8)
Boot
Clip 10 (100, 7)
C–washer
Bellcrank Boot Pin
Adjusting Hole Cup

Plug 10 (100, 7)
Spring
Inspect Hole
Wheel Cylinder
Plug
Adjuster
Pin Return Spring
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13 (130, 9) Rear Shoe
Parking Brake Lever
C–washer
Cup Gasket
Parking Brake Cable No. 1 E–Ring
Drum
Front Shoe Anchor Spring
Automatic
Shoe Hold–down Spring Adjusting Lever
N·m (kgf·cm, ft·lbf) : Specified torque Adjusting Lever Spring
Non–reusable part
Lithium soap base glycol grease
High temperature grease W02711
Author: Date: 1907

BR–33
BR086–03
REMOVAL
1. INSPECT SHOE LINING THICKNESS
Remove the inspection hole plug, and check the shoe lining
thickness through the hole.
If less than the minimum, replace the shoes.
2. REMOVE REAR WHEEL
F07764
3. REMOVE BRAKE DRUM

(a) Release the parking brake lever or pedal and remove the
brake drum.
HINT:
If the brake drum cannot be removed easily, do the following
steps.
(b) Remove the adjusting hole plug from the backing plate.
cardiagn.com
(c) Insert a screwdriver through the hole in the backing plate,
BR3116 and hold the automatic adjusting lever away from the ad-
justing bolt.
(d) Using another screwdriver, reduce the brake shoe adjust-
ment by turning the adjusting bolt.
4. REMOVE REAR SHOE

(a) Using SST, disconnect the return spring from the rear
SST shoe.
SST 09703–30010
(b) Remove the return spring from the front shoe.
R13557
(c) Using SST, remove the shoe hold–down spring, 2 cups

and pin.
SST 09718–00010
(d) Disconnect the anchor spring from the rear shoe and re-
move the rear shoe.
(e) Remove the anchor spring from the front shoe.
SST R13559
Author: Date: 1908

BR–34
5. REMOVE FRONT SHOE

(a) Using SST, remove the shoe hold–down spring, 2 cups
and pin.
SST 09718–00010
(b) Disconnect the parking brake cable No. 1 from the park-
ing brake bellcrank.
(c) Remove the front shoe with adjuster.
SST (d) Disconnect the parking brake cable No. 1 from the front
R13558 shoe.
6. REMOVE ADJUSTER FROM FRONT SHOE
(a) Remove the adjusting lever spring.
(b) Remove the adjuster.
cardiagn.com
7. REMOVE AUTOMATIC ADJUSTING LEVER AND
PARKING BRAKE LEVER
(a) Remove the E–ring.
(b) Remove the automatic adjusting lever.
(c) Remove the C–washer.
(d) Remove the parking brake lever.
Z03633
8. REMOVE AND DISASSEMBLE PARKING BRAKE

BELLCRANK
(a) Remove the clip and pin and disconnect the parking
brake cable.
(b) Remove the 2 tension springs.
(c) Remove the 2 bolts and bellcrank.
W02713
(d) Turn over the bellcrank boot and remove the C–washer
and pin.
(e) Remove the bellcrank bracket and bellcrank boot from the
parking brake bellcrank.
F08895
Author: Date: 1909

BR–35
9. REMOVE WHEEL CYLINDER

SST (a) Using SST, disconnect the brake line. Use a container to
catch the brake fluid.
SST 09023–00100
(b) Remove the 2 bolts and the wheel cylinder.
10. DISASSEMBLE WHEEL CYLINDER
R13561 (a) Remove the 2 boots, 2 pistons and spring.
(b) Remove the 2 piston cups from each piston.
cardiagn.com
Author: Date: 1910

BR–36
BR087–03
INSPECTION
1. INSPECT DISASSEMBLED PARTS
Inspect the disassembled parts for wear, rust or damage.
2. MEASURE BRAKE DRUM INSIDE DIAMETER

Using brake drum gauge or equivalent, measure the inside di-
ameter of the drum.
Standard inside diameter: 295.0 mm (11.614 in.)
Maximum inside diameter: 297.0 mm (11.693 in.)
If the drum is scored or worn, the brake drum may be lathed to
the maximum inside diameter.
cardiagn.com
F06408
3. MEASURE BRAKE SHOE LINING THICKNESS

Using a ruler, measure the shoe lining thickness.
If the shoe lining is less than the minimum, or shows signs of
uneven wear, replace the brake shoes.
HINT:
If any of the brake shoes have to be replaced, replace all of the
BR0047 rear brake shoes in order to maintain even braking.
4. INSPECT BRAKE LINING AND DRUM FOR PROPER

CONTACT
If the contact between the brake lining and drum is improper, re-
pair the lining with a brake shoe grinder, or replace the brake
shoe assembly.
BR0048
Author: Date: 1911

BR–37
BR10R–01
INSTALLATION
Installation is in the reverse order of removal (See page
BR–33).
NOTICE:
Apply lithium soap base glycol grease and high tempera-
ture grease to the parts indicated by the arrows
(See page BR–32).
1. ADJUST BELLCRANK
(a) Lightly pull the bellcrank in direction A until there is no
B 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.).
A (c) Lock the adjusting bolt with the lock nut.
Adjusting Bolt (d) Connect the parking brake cable to the parking brake bell-
cardiagn.com
Lock Nut crank and install the pin and clip.
C F05418 (e) Install the 2 tension springs.
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.
F07757
(d) Pull the parking brake lever all the way up or depress the
parking brake pedal all the way until a clicking sound can
no longer be heard.
Z03659
F07755 F08787
Author: Date: 1912

BR–38
3. CHECK CLEARANCE BETWEEN BRAKE SHOES AND

DRUM
(a) Remove the drum.
(b) Measure the brake drum inside diameter and diameter of
the brake shoes. Check that the difference between the
diameters is the correct shoe clearance.
Shoe clearance: 0.5 mm (0.020 in.)
If it is incorrect, check the parking brake system.
4. FILL BRAKE RESERVOIR WITH BRAKE FLUID
5. BLEED BRAKE SYSTEM (See page BR–4)
6. CHECK FOR LEAKS
cardiagn.com
F07765
Author: Date: 1913

BRAKE – LOAD SENSING PROPORTIONING AND BY–PASS BR–39
VALVE (LSP & BV)
LOAD SENSING PROPORTIONING

AND BY–PASS VALVE (LSP & BV) BR09R–05
1. SET REAR AXLE LOAD
Rear axle load (includes vehicle weight):
Standard cab: 950 kg (2,094 lb)
Access cab:
BR0060
5VZ–FE engine: 1,000 kg (2,205 lb)
2UZ–FE engine: 1,050 kg (2,315 lb)
cardiagn.com
2. INSTALL LSPV GAUGE (SST) AND BLEED AIR
SST SST 09709–29018
BR0061
3. RAISE FRONT BRAKE PRESSURE TO 7,845 kPa (80

80 kgf/cm2
kgf/cm2, 1,138 psi) AND CHECK REAR BRAKE PRES-
SURE
Rear brake pressure:
5,110 ± 490 kPa (52.1 ± 5 kgf/cm2, 741 ± 71 psi)
HINT:
The brake pedal should not be depressed twice and/or returned
while setting to the specified pressure. Read the value of rear
BR0062 brake pressure after holding the specified fluid pressure for 2
seconds. If the brake pressure is incorrect, adjust the fluid pres-
sure.
Author: Date: 1914

BR–40 BRAKE – LOAD SENSING PROPORTIONING AND BY–PASS
VALVE (LSP & BV)
4. IF NECESSARY, ADJUST FLUID PRESSURE

(a) Loosen the lock nut.
(b) Adjust the length of the shackle No. 2.
Low pressure: Lengthen A
High pressure: Shorten A
A
Initial set: 120 mm (4.72 in.)
Adjustment range: 112 – 128 mm (4.41 – 5.04 in.)
HINT:
BR3278 One turn of the nut changes the fluid pressure as shown in the
following specification.
7.4 kPa (0.76 kgf/cm, 11 psi)
(c) Torque the lock nut.
cardiagn.com
(d) If the pressure cannot be adjusted by the shackle No. 2,
raise or lower the valve body.
Low pressure–Lower body
High pressure–Raise body
(e) Torque the nuts.
(f) Adjust the length of the shackle No. 2 again.
If it cannot be adjusted, inspect the valve body.
F07763
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 the load sensing spring or move it.
F07763 BR0218
F08451
(b) In this position, check the rear brake pressure.

Front brake pressure Rear brake pressure
kPa (kgf/cm2, psi) kPa (kgf/cm2, psi)
1,470 (15, 213) 1,470 (15, 213)
3,922 (40, 569) 2,210 ± 390 (22.5 ± 4, 320 ± 57)
13,720 (140, 1,990) 5,150 ± 590 (52.5 ± 6, 767 ± 85)
If the measured value is not within the standard, replace the
valve body.
Z03643
Author: Date: 1915

VALVE (LSP & BV)
BR09S–05
COMPONENTS
Load Sensing Valve Boot
Collar Load Sensing Valve
29 (300, 22) Set Plate
Bushing
Bushing Valve Bracket
15 (155, 11)
Load Sensing Spring 29 (300, 22)
Bushing 15 (155, 11)
Load Sensing Spring Boot Clip

13 (130, 9) 15 (155, 11)
18 (185, 13)
Load Sensing Spring Assembly
Plate Washer
18 (185, 13) Plate Washer
Shackle No. 1
cardiagn.com
13 (130, 9) Plate Washer
Shackle No. 2
Cushion Retainer
Collar x2
Shackle Bracket
Bushing
Lithium soap base glycol grease 29 (300, 22)
F08449
Author: Date: 1916

VALVE (LSP & BV)
BR09T–02
REMOVAL
1. DISCONNECT SHACKLE NO. 2 FROM BRACKET
(a) Remove the nut and cushion retainer, and disconnect the
shackle No. 2.
(b) Remove the 2 bushings and collar.
(c) Remove the 2 bolts and shackle bracket.
R09582
2. REMOVE LSP & BV ASSEMBLY

(a) Using SST, disconnect the 3 brake lines from the valve
SST
body.
SST 09751–36011
(b) Remove the 2 valve bracket mounting bolts and the LSP
& BV assembly.
cardiagn.com
F07762
Author: Date: 1917

VALVE (LSP & BV)
BR10S–01
DISASSEMBLY
1. REMOVE VALVE BRACKET
(a) Remove the nut, washer, bolt and 2 plate washers.
(b) Remove the 2 nuts, 2 washers, set plate and valve brack-
et from the valve body.
R13574
2. DISCONNECT SPRING FROM VALVE

Using pliers, remove the clip, and remove the spring from the
valve.
cardiagn.com
R13575
3. REMOVE SHACKLES NO. 1 AND NO. 2

(a) Remove the nut washer and bolt, and remove the load
sensing spring and 2 plate washers.
(b) Loosen the 2 nuts and plate washer plate, and remove
the shackle No. 1 from the shackle No. 2.
R13576
4. DISASSEMBLE LOAD SENSING SPRING

(a) Remove the 4 bushings and 2 collars.
(b) Remove the load sensing valve boot and load sensing
spring boot.
F08892
Author: Date: 1918

VALVE (LSP & BV)
BR09V–05
INSPECTION
INSPECT VALVE PISTON PIN AND LOAD SENSING CON-
TACT SURFACE FOR WEAR
Wear limit: 0.7 mm (0.028 in.)
Wear Limit 0.7 mm

Z03645
cardiagn.com
Author: Date: 1919

VALVE (LSP & BV)
BR10T–01
REASSEMBLY
1. ASSEMBLE LOAD SENSING SPRING
(a) Install the load sensing valve boot and load sensing
spring boot.
(b) Install the 2 collars and 4 bushings.
HINT:
Apply lithium soap–base glycol grease to all rubbing
areas.
F08892
Do not mistake the valve side for the shackle side of the
load sensing spring.
2. INSTALL SHACKLE NO. 1 AND NO. 2
Install the lock nut, plate washer and shackle No. 1 to the
shackle No. 2 then install the upper nut.
Valve Side Shackle Side 3. INSTALL LOAD SENSING SPRING TO SHACKLE
cardiagn.com
NO. 1
BR0070 (a) Install the load sensing spring and 2 plate washers to the
shackle No. 1.
(b) Install the bolt, washer and nut.
4. INSTALL LOAD SENSING SPRING TO VALVE BODY
Install the load sensing spring to the load sensing valve with the
clip.
5. INSTALL VALVE BRACKET
(a) Install the set plate to the load sensing valve through the
valve bracket and temporarily tighten the 2 washers and
2 nuts.
(b) Install the load sensing spring assembly, 2 plate washers,
bolt, washer and nut.
Author: Date: 1920

VALVE (LSP & BV)
BR09X–02
INSTALLATION
1. INSTALL LSP & BV ASSEMBLY TO FRAME
Install the LSP & BV assembly and 2 valve bracket mounting
bolts.
2. CONNECT BRAKE LINE
Using SST, connect the 3 brake lines.
SST Torque: 15 N·m (155 kgf·cm, 11 ft·lbf)
F07762
SST 09751–36011
3. CONNECT SHACKLE NO. 2 BRACKET

(a) Set dimension A and torque the lock nut.
Initial set: 120 mm (4.72 in.)
(b) Install the shackle bracket and 2 bolts.
A Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
(c) Connect the 2 bushings, collar and shackle No. 2 to the
cardiagn.com
shackle bracket.
Z11333 Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
(d) Install the cushion retainer and nut.
4. SET REAR AXLE LOAD (See page BR–39)
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 2 valve body mounting nuts.
BR0218
6. BLEED BRAKE LINE (See page BR–4)

SST 7. CHECK AND ADJUST LSP & BV FLUID PRESSURE
(See page BR–39)
BR0061
Author: Date: 1921

BR–47
BRAKE – ABS ACTUATOR
ABS ACTUATOR BR10Z–01
1. CONNECT TOYOTA HAND–HELD TESTER
(a) Connect the TOYOTA hand–held tester to the DLC3.
(b) Start the engine and run it at idle.
TOYOTA (c) Select the ACTIVE TEST mode on the TOYOTA hand–
Hand–held
Tester held tester.
DLC3 D05981
HINT:
Please refer to the TOYOTA hand–held tester operator’s manu-
al for further details.
2. INSPECT ABS ACTUATOR MOTOR OPERATION
(a) Check that the operation sound of the ABS actuator mo-
tor can be heard when the motor relay is turned ON by the
TOYOTA hand–held tester.
NOTICE:
Do not keep motor relay ON for more than 5 seconds con-
cardiagn.com
tinuously. When operating it continuously, set the interval
of more than 20 seconds.
If the operation sound can be heard, replace the ABS actuator
because the motor operation is in failure.
(b) Turn the motor relay OFF.
3. INSPECT RIGHT FRONT WHEEL SOLENOID
(a) Depress the brake pedal and hold it for about 15 seconds,
and check that the brake pedal does not go down further.
If the brake pedal goes down, replace the ABS actuator be-
cause the sealing condition of the reduction solenoid valve is
abnormal.
(b) Check that the brake pedal does not pulsate when the
motor relay is turned ON by the TOYOTA hand–held tes-
ter.
NOTICE:
If there is a pulsation in the brake pedal, replace the ABS actua-
tor because the sealing condition of the reduction solenoid
valve is abnormal.
(c) Turn the motor relay OFF.
(d) Depress the brake pedal and hold it until the step (g) is
completed.
(e) Check that the brake pedal does not go down further
when the SFRH and SFRR solenoids are turned ON by
the TOYOTA hand–held tester.
NOTICE:
Do not keep solenoid ON for more than 2 seconds continu-
ously. When operating it continuously, set the interval of
more than 20 seconds.
If the brake pedal goes down, replace the ABS actuator be-
cause the holding solenoid valve operation is abnormal.
Author: Date: 1922

BR–48
HINT:
To prevent the solenoids, TOYOTA hand–held tester turns OFF
automatically 2 secs. after has been turned ON simultaneously.
(f) Check that the brake pedal goes down further when the
solenoids are turned OFF.
If the brake pedal does not go down, replace the ABS actuator
because the reduction solenoid valve operation is abnormal.
(g) Check that the brake pedal returns when the motor relay
is turned ON by the TOYOTA hand–held tester.
NOTICE:
If the brake pedal does not return, replace the ABS actuator be-
cause the motor operation is in failure.
(h) Turn the motor relay OFF and release the brake pedal.
4. INSPECT OTHER WHEEL SOLENOIDS OPERATION
cardiagn.com
Check the solenoids of the other wheels with the same inspec-
tion procedure as the right front wheel solenoids.
HINT:
Left front wheel: SFLH and SFLR
Right rear wheel: SRRH and SRRR
Left rear wheel: SRLH and SRLR
NOTICE:
Never depress the brake pedal under the condition that the
reduction solenoid alone is turned ON as ABS ECU is reset.
5. CLEAR DTC (See page DI–448)
Author: Date: 1923

BR–49
BR10U–01
COMPONENTS
15 (155, 11)
19 (195, 14)
ABS Actuator Assembly
19 (195, 14)
cardiagn.com
8.0 (82, 71 in.·lbf)
Holder
Cushion
ABS Actuator
Holder
Cushion
ABS Actuator Bracket

F07766
Author: Date: 1924

BR–50
4.4 (45, 39 in.·lbf)
ABS ECU
4.4 (45, 39 in.·lbf)
ABS Actuator
cardiagn.com
2.9 (30, 26 in.·lbf)
Clamp

F08427
Author: Date: 1925

BR–51
BR10V–01
REMOVAL
1. REMOVE BRAKE LINE COVER
2. DISCONNECT CONNECTOR
Pull out the release bar, and disconnect the connector.
F07767
3. DISCONNECT BRAKE LINES

SST Using SST, disconnect the 5 brake lines from the ABS actuator.
SST 09023–00100
4. REMOVE ABS ACTUATOR ASSEMBLY
Remove the 3 nuts and ABS actuator assembly.
cardiagn.com
5. REMOVE ABS ACTUATOR
F08185 (a) Remove the 3 nuts and ABS actuator from the actuator
bracket.
(b) Remove the 3 holders and 3 cushions from the ABS ac-
tuator.
Author: Date: 1926

BR–52
BR10W–01
DISASSEMBLY
1. DISCONNECT CONNECTOR
(a) Remove the screw and clamp from the ABS actuator.
(b) Disconnect the connector.
2. REMOVE ABS ECU
Using a hexagon wrench (4 mm), remove the 4 bolts and ABS
ECU.
NOTICE:
Sealing
Surface Protect the actuator in order to prevent sealing surface
from getting dirty and causing damage on the valve body.
If the dirt and the like is stuck to the sealing surface, use
plastic tools or soft objects to remove the dirt. Do not use
chemical solvents.
cardiagn.com
F06220
Author: Date: 1927

BR–53
BR10X–01
REASSEMBLY
cardiagn.com
Author: Date: 1928

BR–54
BR10Y–01
INSTALLATION
HINT:
Check for leaks.
cardiagn.com
Author: Date: 1929

BR–55
BRAKE – FRONT SPEED SENSOR
FRONT SPEED SENSOR

BR0A2–02
COMPONENTS
8.0 (82, 71 in.·lbf)
8.0 (82, 71 in.·lbf)
8.0 (82, 71 in.·lbf)
cardiagn.com
Front Speed Sensor
F08184
Author: Date: 1930

BR–56
BR0A3–02
REMOVAL
2. DISCONNECT SPEED SENSOR CONNECTOR
3. REMOVE SPEED SENSOR
(a) Remove the clips and 3 clamp bolts holding the sensor
harness from the frame, upper arm and steering knuckle.
F08186
(b) Remove the bolt and speed sensor from the steering
knuckle.
cardiagn.com
Author: Date: 1931

BR–57
BR0A4–02
INSTALLATION
HINT:
After installation, check speed sensor signal (See page DI–448).
cardiagn.com
Author: Date: 1932

BR–58
BRAKE – REAR SPEED SENSOR
REAR SPEED SENSOR

BR0A5–02
COMPONENTS
8.0 (82, 71 in.·lbf)
8.0 (82, 71 in.·lbf)
Rear Speed Sensor
13 (130, 9)
N·m (kgf·cm, ft·lbf) : Specified torque F08448
cardiagn.com
Author: Date: 1933

BR–59
BR0A6–02
REMOVAL
1. DISCONNECT SPEED SENSOR CONNECTOR
2. REMOVE SPEED SENSOR
(a) Remove the 2 clamp bolts, clamp nut and 5 resin clips
holding the sensor wire harness from the axle and the fuel
tank.
HINT:
R12233
When installing the rear sensor wire harness, never use
the removed resin clips, which are service parts.
When replacing clips, set up new resin clips at the same
angle of the removed resin clips.
(b) Remove the bolt and speed sensor from the axle carrier.
cardiagn.com
Author: Date: 1934

BR–60
BR0A7–02
INSTALLATION
HINT:
After installation, check speed sensor signal (See page DI–448).
cardiagn.com
Author: Date: 1935

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BR–1

BRAKE – BRAKE SYSTEM

2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1876

PROBLEM SYMPTOMS TABLE

1. Brake pedal freeplay (Minimum) BR–6

1. Piston (Stuck) BR–26

2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1877

1. Fluid leaks for brake system DI–487

2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1878

BRAKE FLUID BR08Q–02

3. BLEED BRAKE LINE

Author: Date: 1879

(e) Repeat the procedure on the previous page to bleed the

2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1880

BRAKE PEDAL BR107–01

Stop Light Switch ON–VEHICLE INSPECTION

3. CHECK PEDAL FREE PLAY

2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1881

4. CHECK PEDAL RESERVE DISTANCE

2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1882

Lower Finish Panel

Hood Lock Release Lever

Stop Light Switch

Clip Brake Pedal

Pin Brake Pedal

Front Door Scuff Plate

N·m (kgf·cm, ft·lbf) : Specified torque

2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1883

PARKING BRAKE PEDAL BR109–01

2. IF NECESSARY, ADJUST PARKING BRAKE PEDAL

2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1884

Hood Lock Release Lever

Cowl Side Trim

Front Door Scuff Plate

N·m (kgf·cm, ft·lbf) : Specified torque

2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1885

2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1886

2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1887

PARKING BRAKE LEVER BR10D–01

2. IF NECESSARY, ADJUST PARKING BRAKE

2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1888

BRAKE MASTER CYLINDER

Level Warning Switch Connector

15 (155, 11) Brake Booster

13 (130, 9) 15 (155, 11)

Wire Harness Bracket