BR−16

BRAKE SYSTEM − BRAKE BOOSTER

BRAKE BOOSTER
BRAKE BOOSTER REMOVAL

1. REMOVE MASTER CYLINDER

(See page BR−11)
2. DISCONNECT VACUUM HOSE FROM BRAKE BOOSTER
3. REMOVE PEDAL RETURN SPRING
4. REMOVE CLIP AND CLEVIS PIN

5. REMOVE BRAKE BOOSTER, GASKET AND CLEVIS

 BR−17
BRAKE SYSTEM − BRAKE BOOSTER

BRAKE BOOSTER INSTALLATION

1. ADJUST LENGTH OF BOOSTER PUSH ROD
(a) Install the gasket on the master cylinder.
(b) Set the SST on the gasket, and lower the pin until its tip
slightly touches the piston.
SST 09737−00010

(c) Turn the 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 lightly
touches the pin head.

2. INSTALL BRAKE BOOSTER, GASKET AND CLEVIS

(a) Install the booster and a new gasket.
(b) Install the clevis.
(c) Install and torque the booster mounting nuts.
Torque: 13 N⋅m (130 kgf⋅cm, 9 ft⋅lbf)
3. CONNECT CLEVIS TO BRAKE PEDAL
Insert the clevis pin into the clevis and brake pedal and install
the clip to the clevis pin.
4. INSTALL PEDAL RETURN SPRING
5. INSTALL MASTER CYLINDER
(See page BR−11)
6. CONNECT VACUUM HOSE TO BRAKE BOOSTER
7. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND
BLEED BRAKE SYSTEM
(See page BR−9)
8. CHECK FOR FLUID LEAKAGE
9. CHECK AND ADJUST BRAKE PEDAL
(See page BR−7)
10. PERFORM OPERATIONAL CHECK
(See page BR−9)
 BR−7
BRAKE SYSTEM − CHECK AND ADJUSTMENT

CHECK AND ADJUSTMENT

BRAKE PEDAL CHECK AND
ADJUSTMENT
1. CHECK THAT PEDAL HEIGHT IS CORRECT, AS SHOWN
Pedal height from asphalt sheet:
2WD:
148 mm (5.83 in.)
4WD:
145 mm (5.71 in.)
2. IF NECESSARY, ADJUST PEDAL HEIGHT
(a) Disconnect the connector from the stop light switch.
(b) Loosen the stop light switch lock nut and remove the stop
light switch.
(c) Loosen the push rod lock nut.
(d) Adjust the pedal height by turning the pedal push rod.
(e) Tighten the push rod lock nut.
Torque: 25 N⋅m (260 kgf⋅cm, 19 ft⋅lbf)
(f) Install the stop light switch and turn it until it lightly contacts
the pedal stopper.
(g) Turn the stop light switch back one turn.
(h) Check that the clearance (A) between stop light switch and
pedal.
Clearance:
0.5−2.4 mm (0.02−0.09 in.)
(i) Tighten the stop light switch lock nut.
(j) Check that the stop lights come on when the brake pedal is
depressed, and go off when the brake pedal is released.
(k) After adjusting the pedal height, check the pedal free play.
HINT: If clearance (A) between the stop light switch and the
pedal stopper has been adjusted correctly, the pedal freeplay
will meet the specifications.
BR−8
BRAKE SYSTEM − CHECK AND ADJUSTMENT

3. CHECK THAT PEDAL FREEPLAY IS CORRECT, AS

SHOWN
(a) Stop the engine and depress the brake pedal several times
until there is no more vacuum left in the booster.
(b) Single booster:
Push in the pedal until the beginning of resistance is felt.
Measure the distance, as shown.
Pedal freeplay:
3−6 mm (0.12−0.24 in.)
Tandem booster:
Push in the pedal by hand until the beginning of the second
resistance is felt. Measure the distance, as shown.
Pedal freeplay:
3−6 mm (0.12−0.24 in.)
HINT: The freeplay to the 1st resistance is due to the play be-
tween the clevis and pin. This is magnified up to 1−3 mm
(0.04−0.12 in.) at the pedal.

4. CHECK THAT PEDAL RESERVE DISTANCE IS CORRECT,

AS SHOWN
Release the parking brake.
With 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):
2WD:
22R−E Engine
More than 70 mm (2.76 in.)
3VZ−E Engine
More than 65 mm (2.56 in.)
4WD:
More than 65 mm (2.56 in.)
If incorrect, troubleshoot the brake system.
 BR−9
BRAKE SYSTEM − CHECK AND ADJUSTMENT

BRAKE BOOSTER OPERATIONAL TEST

HINT: If available, use a brake booster tester to check the
booster operating condition.
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 engine. If the pedal goes
down slightly, operation is normal.
2. AIR TIGHTNESS CHECK
(a) Start the engine and stop it after 1 or 2 minutes.
Depress the brake pedal several times slowly.
If the pedal goes down furthest 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
stop it with the pedal depressed. If there is no change in pedal
reserve travel after holding the pedal for 30 seconds, the
booster is air tight.

BRAKE SYSTEM BLEEDING

HINT: If any work is done on the brake system or if air is sus-
pected in the brake lines, bleed the system of air.
NOTICE: Do not let brake fluid remain on a painted sur-
face. Wash it off immediately.
1. FILL BRAKE RESERVOIR WITH BRAKE FLUID
Check the fluid level in the reservoir after bleeding each
wheel. Add fluid, if necessary.

2. BLEED MASTER CYLINDER

HINT: If the master cylinder was disassembled or if the reser-
voir becomes empty, bleed the air from the master cylinder.
(a) Disconnect the brake lines from the master cylinder.
(b) Slowly depress the brake pedal and hold it.

(c) Block off the outlet plug with your finger, and release the
brake pedal.
(d) Repeat (b) and (c) 3 or 4 times.
BR−10
BRAKE SYSTEM − CHECK AND ADJUSTMENT

3. CONNECT VINYL TUBE TO WHEEL CYLINDER

BLEEDER PLUG
Insert other end of the tube in a half−full container of brake
fluid.
HINT: Begin air bleeding from the wheel cylinder with the
longest hydraulic line.
4. BLEED BRAKE LINE
(a) Slowly depress the brake pedal several times.
(b) While an assistant depresses the pedal, loosen the bleeder
plug until fluid starts to run out. Then close the bleeder plug.
(c) Repeat this procedure until there are no more air bubbles in
the fluid.
Bleeder plug tightening torque:
11 N⋅m (110 kgf⋅cm, 8 ft⋅lbf)
5. REPEAT PROCEDURE FOR EACH WHEEL
6. BLEED LSP & BV

PARKING BRAKE CHECK AND

ADJUSTMENT
1. CHECK THAT PARKING BRAKE LEVER TRAVEL IS
CORRECT
Pull the parking brake level all the way up, and count the num-
ber of clicks.
Parking brake lever travel at 196 N (20 kgf, 44.1 lbf):
2WD: 12−18 clicks
4WD: 11−17 clicks
2. IF NECESSARY, ADJUST PARKING BRAKE
HINT: Before adjusting the parking brake, make sure that the
rear brake shoe clearance has been adjusted.
2WD:
(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.

4WD:
(a) Tighten one 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 bellcrank
stopper screw comes into contact with the backing plate.
BR−2
BRAKE SYSTEM − DESCRIPTION

GENERAL DESCRIPTION
1. 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 of the same part number or
equivalent.
2. It is very important to keep parts and the area clean when repairing the brake system.
3. If the vehicle is equipped with a mobile communication system, refer to the precaution in the IN
section.

DESCRIPTION
The service brakes consist of a foot brake which changes rotational energy to thermal energy to stop the
vehicle while it is being driven and a parking brake to keep the vehicle from moving while it is parked.

OPERATION
FOOT BRAKE
When the brake pedal is depressed, a vacuum builds up in the booster which amplifies the pedal force,
pressing on the piston in the master cylinder. The piston movement raises the hydraulic pressure in the
cylinder. This hydraulic pressure is then applied to each respective brake cylinder and wheel cylinder, and
acts to press the brake pads and shoes against the rotating discs and drum. The resulting friction converts
the rotational energy to thermal energy, stopping the vehicle.
BR−18
BRAKE SYSTEM − FRONT BRAKE 2WD

FRONT BRAKE 2WD

COMPONENTS

BRAKE PADS REPLACEMENT

1. REMOVE FRONT WHEEL
2. INSPECT PAD LINING THICKNESS
Check the pad thickness through the caliper inspection hole
and replace pads if not within specification.
Minimum thickness:
1.0 mm (0.039 in.)

3. LIFT UP CALIPER
(a) Remove the sliding sub pin from the torque plate.
 BR−19
BRAKE SYSTEM − FRONT BRAKE 2WD

(b) Lift up the caliper and suspend it, making sure the hose is not
stretched.
HINT: Do not disconnect the brake hose.

4. REMOVE FOLLOWING PARTS:

(a) 2 brake pads
(b) 4 anti−squeal shims
(c) 2 pad wear indicator plates
(d) 4 pad support plates
5. CHECK DISC THICKNESS AND RUNOUT
(See page BR−21)

6. INSTALL PAD SUPPORT PLATES

7. INSTALL NEW PADS

(a) Install a pad wear indicator plate to the pad.
(b) Install the 2 anti−squeal shims to each pad.
HINT: Apply disc brake grease to both side of the inner anti−
squeal shim.

(c) Install the 2 pads so that the wear indicator plate is facing
underneath.
NOTICE: Do not allow oil or grease to get on the rubbing
face.
BR−20
BRAKE SYSTEM − FRONT BRAKE 2WD

8. INSTALL CALIPER
(a) Draw out a small amount of brake fluid from the reservoir.
(b) Press in piston with a hammer handle or an equivalent.
HINT: Always change the pad on one wheel at a time as there
is a possibility of the opposite piston flying out.
(c) Insert the caliper carefully so that the boot is not wedged.

(d) Install and torque the sliding sub pin.

Torque: 88 N⋅m (900 kgf⋅cm, 65 ft⋅lbf)
9. INSTALL FRONT WHEEL
10. CHECK THAT FLUID LEVEL IS AT MAX LINE

CALIPER REMOVAL
1. DISCONNECT BRAKE LINE
(a) Using SST, disconnect the brake line. Use a container to
catch the brake fluid.
SST 09751−36011
(b) Remove the bracket from the caliper.

2. REMOVE CALIPER FROM TORQUE PLATE

(a) Remove the sliding main pin and sliding sub pin.
(b) Remove the caliper.
3. REMOVE PADS
(See step 4 on page BR−19)

CALIPER DISASSEMBLY
1. REMOVE PISTON FROM CALIPER
(a) Put a piece of cloth or an equivalent between the piston and
caliper.
(b) Use compressed air to remove the piston and cylinder boot
from the caliper.
CAUTION: Do not place your fingers in front of the piston
when using compressed air.
 BR−21
BRAKE SYSTEM − FRONT BRAKE 2WD

2. REMOVE PISTON SEAL FROM CALIPER

Using a screwdriver, remove the piston seal.

FRONT BRAKE COMPONENTS

INSPECTION AND REPAIR
1. MEASURE PAD LINING THICKNESS
Standard thickness:
USA STD Model: 9.5 mm (0.374 in.)
Others: 10.0 mm (0.394 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

Standard thickness:
22.0 mm (0.866 in.)
Minimum thickness:
20.0 mm (0.787 in.)
If the disc is scored or worn, or if its thickness is less than mini-
mum, repair or replace the disc.

3. MEASURE DISC RUNOUT

HINT: Before measuring the runout, confirm that the front hub
bearing play is within specification.
Measure the disc runout at 10 mm (0.39 in.) from the outer
edge of the disc.
Maximum disc runout:
0.09 mm (0.0035 in.)
BR−22
BRAKE SYSTEM − FRONT BRAKE 2WD

4. IF NECESSARY, REPLACE DISC

(a) Remove the torque plate from the knuckle.
(b) Remove the axle hub. (See page SA−14)
(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−17)
(f) Install the torque plate onto the knuckle.
Torque: 108 N⋅m (1,100 kgf⋅cm, 80 ft⋅lbf)

CALIPER ASSEMBLY
1. APPLY LITHIUM SOAP BASE GLYCOL GREASE TO
PARTS INDICATED WITH ARROWS

2. INSTALL PISTON SEAL IN CALIPER

3. INSTALL PISTON AND CYLINDER BOOT IN CALIPER

4. INSTALL PIN BOOT AND CALIPER SLIDING BUSHING

(a) Install the pin boot into the sliding sub pin side.
(b) Using a plastic bar, install the caliper sliding bushing into the
sliding sub pin side.
 BR−23
BRAKE SYSTEM − FRONT BRAKE 2WD

CALIPER INSTALLATION
1. INSTALL PADS
(See steps 6 of 7 on page BR−19)

2. INSTALL CALIPER
(a) Install the caliper.
(b) Install and torque the 2 sliding pins.
Torque: 88 N⋅m (900 kgf⋅cm, 65 ft⋅lbf)

3. CONNECT BRAKE LINE

(a) Install the bracket to the caliper.
Torque: 18 N⋅m (185 kgf⋅cm, 13 ft⋅lbf)
(b) Using SST, connect the brake line to the caliper.
SST 09751−36011
Torque: 15 N⋅m (155 kgf⋅cm, 11 ft⋅lbf)
4. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND
BLEED BRAKE SYSTEM
(See page BR−9)
5. CHECK FOR FLUID LEAKAGE
 BR−1

BRAKE SYSTEM
BR−2
BRAKE SYSTEM − GENERAL DESCRIPTION

GENERAL DESCRIPTION
1. 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 of the same part number or
equivalent.
2. It is very important to keep parts and the area clean when repairing the brake system.
3. If the vehicle is equipped with a mobile communication system, refer to the precaution in the IN
section.

DESCRIPTION
The service brakes consist of a foot brake which changes rotational energy to thermal energy to stop the
vehicle while it is being driven and a parking brake to keep the vehicle from moving while it is parked.

OPERATION
FOOT BRAKE
When the brake pedal is depressed, a vacuum builds up in the booster which amplifies the pedal force,
pressing on the piston in the master cylinder. The piston movement raises the hydraulic pressure in the
cylinder. This hydraulic pressure is then applied to each respective brake cylinder and wheel cylinder, and
acts to press the brake pads and shoes against the rotating discs and drum. The resulting friction converts
the rotational energy to thermal energy, stopping the vehicle.
BR−46
BRAKE SYSTEM − LOAD SENSING PROPORTIONING AND BYPASS VALVE LSP & BV

LOAD SENSING PROPORTIONING

AND BYPASS VALVE LSP & BV
COMPONENTS

FLUID PRESSURE INSPECTION

1. SET REAR AXLE LOAD
Rear axle load (includes vehicle weight):
2WD: 700 kg (1,543 lb)
4WD: 800 kg (1,764 lb)

2. INSTALL LSPV GAUGE (SST) AND BLEED AIR

SST 09709−29017
 BR−47
BRAKE SYSTEM − LOAD SENSING PROPORTIONING AND BYPASS VALVE LSP & BV

3. RAISE FRONT BRAKE PRESSURE TO 7,845 kPa (80

kgf/cm 2 , 1,138 psi) AND CHECK REAR BRAKE
PRESSURE
Rear brake pressure:
2WD:
3,922−4,903 kPa (40−50 kgf/cm2, 569−711 psi)
4WD:
Regular cab
3,433−4,413 kPa (35−45 kgf/cm2, 498−640 psi)
Extra cab
3,825−4,805 kPa (39−49 kgf/cm2, 555−697 psi)
HINT: The brake pedal should not be depressed twice and/or
returned while setting to the specified pressure. Read the val-
ue of rear brake pressure 2 seconds after adjusting the speci-
fied fluid pressure.
If the brake pressure is incorrect, adjust the fluid pressure.

4. IF NECESSARY, ADJUST FLUID PRESSURE

(a) Adjust the length of the No.2 shackle.
Low pressure: Lengthen A
High pressure: Shorten A
Initial set:
2WD
78 mm (3.07 in.)
4WD
120 mm (4.72 in.)
Adjustment range:
2WD
72−84 mm (2.83−3.31 in.)
4WD
114−126 mm (4.49−4.96 in.)
HINT: 1 turn of the nut changes the fluid pressure as shown

ÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑ
in the table below.

ÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑ
2WD

ÑÑÑÑÑÑÑÑÑÑÑÑ
74 kPa (0.75 kgf/cm2, 11 psi)

ÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑ
4WD 59 kPa (0.6 kgf/cm2, 8.5 psi)

(b) In event the pressure cannot be adjusted by the No.1

shackle, raise or lower the valve body.
Low pressure−Lower body
High pressure−Raise body
(c) Torque the nuts.
Torque: 13 N⋅m (130 kgf⋅cm, 9 ft⋅lbf)
(d) Adjust the length of the No.1 shackle again.
If it cannot be adjusted, inspect the valve housing.
BR−48
BRAKE SYSTEM − LOAD SENSING PROPORTIONING AND BYPASS VALVE LSP & BV

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 1 mm (0.04 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.

ÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑ
2WD:

ÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑ
Front brake pressure Rear brake pressure

ÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑ
kPa (kgf/cm2, psi) kPa (kgf/cm2, psi)

ÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑ
1,471 (15,213) 1,471 (15,213)

ÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑ
1,667−1,961
3,432 (35,498)

ÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑ
(17−21, 242−284)

ÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑ
2,206−2,893
6,865 (70,996)

ÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑ
(22.5−29.5, 320−419)

ÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑ
4WD (Regular cab)

ÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑ
Front brake pressure

ÑÑÑÑÑÑÑÑÑÑÑÑ
kPa (kgf/cm2, psi)
Rear brake pressure
kPa (kgf/cm2, psi)

ÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑ
981 (10,142) 981 (10,142)

ÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑ 1,079−1,471

ÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑ
2,452 (25,356)
(11−15, 156−213)

ÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑ
5,884 (60,853)

ÑÑÑÑÑÑÑÑÑÑÑÑ
1,618−2,305
(16.5−23.5, 235−334)

4WD (Extra cab)

ÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑ
Front brake pressure
kPa (kgf/cm2, psi)
Rear brake pressure
kPa (kgf/cm2, psi)

ÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑ
981 (10,142)

ÑÑÑÑÑÑÑÑÑÑÑÑ
981 (10,142)

ÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑ
1,157−1,549
2,452 (25,356)
(11.8−15.8, 168−225)

ÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑ 1,863−2,550

ÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑ
5,884 (60,853)
(19−26, 270−370)

If the measured value is not within standard, replace the

valve body.
LSP & BV or LSPV REMOVAL
1. DISCONNECT SHACKLE NO.2 FROM BRACKET
 BR−49
BRAKE SYSTEM − LOAD SENSING PROPORTIONING AND BYPASS VALVE LSP & BV

2. REMOVE LSP & BV (LSPV) ASSEMBLY

(a) Using SST, disconnect the brake lines from the valve body.
SST 09751−36011
(b) Remove the valve bracket mounting bolts and remove the
LSP & BV (LSPV) assembly.

LSP & BV or LSPV DISASSEMBLY

1. REMOVE VALVE BRACKET
(a) Remove the nut and bolt, as shown.
(b) Remove the 2 nuts, and remove the bracket and set plate
from the valve body.

2. DISCONNECT SPRING FROM VALVE

Using pliers, remove the clip, and remove the spring from the
valve.

3. REMOVE SHACKLES NO.1 AND NO.2

Remove the nuts and bolts, and then remove No.1 and No.2
shackle, and 2 plate washers from the load sensing spring
assembly.

4. DISASSEMBLE LOAD SENSING SPRING

Disassemble the following parts.
(a) Bushings
(b) Collars
(c) Rubber plates
(d) Load sensing valve boot
(e) Load sensing spring boot
BR−50
BRAKE SYSTEM − LOAD SENSING PROPORTIONING AND BYPASS VALVE LSP & BV

LSP & BV or LSPV INSPECTION

INSPECT VALVE PISTON PIN AND LOAD SENSING CON-
TACT SURFACE FOR WEAR
Wear limit:
0.7 mm (0.028 in.)

LSP & BV or LSPV ASSEMBLY

1. ASSEMBLE FOLLOWING PARTS TO LOAD SENSING
SPRING:
(a) Load sensing valve boot
(b) Load sensing spring boot
(c) Bushings
(d) Rubber plates
(e) Collars

HINT: Apply lithium soap−base glycol grease to all rubbing

areas.
Do not mistake the valve side for the shackle side of the load
sensing spring.

2. ASSEMBLE VALVE BODY TO BRACKET

Assemble the valve body to the valve body bracket.
HINT: Finger tighten the valve body mounting nuts.

3. CONNECT VALVE BODY AND NO.1 SHACKLE TO LOAD

SENSING SPRING
CAUTION: When connecting the shackle to the load
sensing with a bolt and nut, insert the bolt from the front
side of vehicle.
 BR−51
BRAKE SYSTEM − LOAD SENSING PROPORTIONING AND BYPASS VALVE LSP & BV

LSPV & BV or LSPV INSTALLATION

1. INSTALL LSP & BV (LSPV) ASSEMBLY TO FRAME
Torque: 19 N⋅m (195 kgf⋅cm, 14 ft⋅lbf)
2. CONNECT BRAKE LINE
Using SST, connect the brake lines.
Torque: 15 N⋅m (155 kgf⋅cm, 11 ft⋅lbf)
SST 09751−36011

3. CONNECT SHACKLE NO.2 BRACKET

(a) Install shackle No.2 to the load sensing spring.
(b) Set dimension A.
Initial set:
2WD
78 mm (3.07 in.)
4WD
120 mm (4.72 in.)
(c) Connect the shackle No.2 to the shackle bracket.

4. SET REAR AXLE LOAD

(See page BR−46)
5. SET VALVE BODY
(a) When pulling down the load sensing spring, confirm that the
valve piston moves down smoothly.
(b) Position the valve body so that the valve piston lightly
contacts the load sensing spring.
(c) Tighten the valve body mounting nuts.
6. BLEED BRAKE LINE
(See page BR−9)
7. CHECK AND ADJUST LSP & BV OR LSPV FLUID
PRESSURE
(See page BR−46)
8. APPLY SEALANT TO SHACKLE NO.2
Apply sealant to the top portion of the shackle No.2 bolt
threads not to lose the upper lock nut.
Sealant:
Part No. 08833−00070, THREE BOND 1324 or equivalent
 BR−11
BRAKE SYSTEM − MASTER CYLINDER

MASTER CYLINDER
MASTER CYLINDER REMOVAL

1. DISCONNECT LEVEL WARNING SWITCH CONNECTOR

2. TAKE OUT FLUID WITH SYRINGE
NOTICE: Do not let brake fluid remain on a painted sur-
face. Wash it off immediately.
3. DISCONNECT BRAKE LINES
Using SST, disconnect the brake lines from the master cylin-
der.
SST 09751−36011

4. REMOVE MASTER CYLINDER

(a) Remove the 4 nuts and 3−way union.
(b) Remove the clamp.
(c) Remove the master cylinder and gasket from the brake
booster.
BR−12
BRAKE SYSTEM − MASTER CYLINDER

COMPONENTS

MASTER CYLINDER DISASSEMBLY

1. REMOVE MASTER CYLINDER BOOT
Using a screwdriver, remove the master cylinder boot.

2. REMOVE RESERVOIR
(a) Remove the set screw and pull out the reservoir.
(b) Remove the cap and strainer from the reservoir.
3. REMOVE 2 GROMMETS
4. PLACE CYLINDER IN VISE
 BR−13
BRAKE SYSTEM − MASTER CYLINDER

5. REMOVE PISTON STOPPER BOLT

Using a screwdriver, push the pistons in all the way and re-
move the piston stopper bolt and gasket.
HINT: Tape the screwdriver tip before use.

6. REMOVE PISTONS AND SPRINGS

(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 at an angle, there is a possibility of
damaging the cylinder bore.

(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 cylinder.
HINT: Make sure the distance (A) from the rag to the top of
the blocks is at least 100 mm (3.94 in.).

MASTER CYLINDER COMPONENTS

INSPECTION
HINT: Clean the disassembled parts with compressed air.
1. INSPECT CYLINDER BORE FOR RUST OR SCORING
2. INSPECT CYLINDER FOR WEAR OR DAMAGE
If necessary, clean or replace the cylinder.

MASTER CYLINDER ASSEMBLY

1. APPLY LITHIUM SOAP BASE GLYCOL GREASE TO
RUBBER PARTS INDICATED BY ARROWS
BR−14
BRAKE SYSTEM − MASTER CYLINDER

2. INSTALL PISTONS AND SPRINGS

NOTICE: Be careful not to damage the rubber lips on the
pistons.
(a) Insert the 2 springs and pistons straight in, not at an angle.
NOTICE: If inserted at an angle, there is a possibility of
damaging the cylinder bore.
(b) Push in the piston with a screwdriver and install the snap ring
with snap ring pliers.
HINT: Tape the screwdriver tip before use.

3. INSTALL PISTON STOPPER BOLT

Using a screwdriver, push the piston in all the way and install
the piston stopper bolt over a new gasket.
Torque the bolt.
Torque: 10 N⋅m (100 kgf⋅cm, 7 ft⋅lbf)

4. INSTALL 2 GROMMETS

5. INSTALL RESERVOIR
(a) Install the cap and strainer to the reservoir.
(b) Push the reservoir onto the cylinder.
(c) Install the set screw while pushing on the reservoir.
Torque: 1.7 N⋅m (17.5 kgf⋅cm, 15.2 in.⋅lbf)

6. INSTALL MASTER CYLINDER BOOT

Facing the up mark on the master cylinder boot upwards,
install the cylinder boot to the master cylinder.
 BR−15
BRAKE SYSTEM − MASTER CYLINDER

MASTER CYLINDER INSTALLATION

1. ADJUST LENGTH OF BRAKE BOOSTER PUSH ROD
BEFORE INSTALLING MASTER CYLINDER
(See page BR−17)

2. INSTALL MASTER CYLINDER

Install the master cylinder and gasket on the brake booster
with 4 nuts.
Torque: 13 N⋅m (130 kgf⋅cm, 9 ft⋅lbf)

3. CONNECT BRAKE LINES

Using SST, connect the brake lines to the master cylinder.
Torque the union nuts.
SST 09751−36011
Torque: 15 N⋅m (155 kgf⋅cm, 11 ft⋅lbf)
4. CONNECT LEVEL WARNING SWITCH CONNECTOR
5. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND
BLEED BRAKE SYSTEM
(See page BR−9)
6. CHECK FOR FLUID LEAKAGE
7. CHECK AND ADJUST BRAKE PEDAL
(See page BR−7)
BR−2
BRAKE SYSTEM − OPERATION

GENERAL DESCRIPTION
1. 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 of the same part number or
equivalent.
2. It is very important to keep parts and the area clean when repairing the brake system.
3. If the vehicle is equipped with a mobile communication system, refer to the precaution in the IN
section.

DESCRIPTION
The service brakes consist of a foot brake which changes rotational energy to thermal energy to stop the
vehicle while it is being driven and a parking brake to keep the vehicle from moving while it is parked.

OPERATION
FOOT BRAKE
When the brake pedal is depressed, a vacuum builds up in the booster which amplifies the pedal force,
pressing on the piston in the master cylinder. The piston movement raises the hydraulic pressure in the
cylinder. This hydraulic pressure is then applied to each respective brake cylinder and wheel cylinder, and
acts to press the brake pads and shoes against the rotating discs and drum. The resulting friction converts
the rotational energy to thermal energy, stopping the vehicle.
 BR−3
BRAKE SYSTEM − OPERATION

PARKING BRAKE
When the parking brake lever is pulled, the parking brake shoe lever is pulled via the parking brake wire.
This causes the shoe strut to push the front shoe, which expands and is pressed against the parking brake
drum. If the parking brake lever continues to be pulled, the contact point of the parking brake shoe lever
and shoe strut then becomes the fulcrum so that the parking brake shoe lever causes the parking brake
shoe to expand. This results in the parking brake drum being locked by the right shoe and left shoe.
BR−4
BRAKE SYSTEM − PREPARATION

PREPARATION
SST (SPECIAL SERVICE TOOLS)
09631−22020 Power Steering Hose Nut
14 x 17 mm Wrench Set

09703−30010 Brake Shoe Return Spring Tool

09709−29017 LSPV Gauge Set

09717−20010 Brake Shoe Return Spring Remover

09718−00010 Shoe Hold Down Spring Driver

09718−20010 Brake Shoe Return Spring Replacer

09737−00010 Brake Booster Push Rod Gauge

09751−36011 Brake Tube Union Nut 10 x 12 mm

Wrench

09843−18020 Diagnosis Check Wire

09990−00150 ABS Actuator Checker and

Sub−harness

09990−00250 ABS Actuator Checker

Sub−harness “D”
 BR−5
BRAKE SYSTEM − PREPARATION

EQUIPMENT
ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
Torque wrench
ÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
Micrometer
ÑÑÑÑÑÑÑÑÑÑÑ Brake disc

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
Dial indicator ÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑ
Brake disc

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
Vernier calipers
ÑÑÑÑÑÑÑÑÑÑÑ Brake drum

ÑÑÑÑÑÑÑÑÑÑÑÑÑ
LUBRICANT ÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑ
Item Capacity Classification

ÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑ
Brake fluid − SAE J1703 or FMVSS No. 116 DOT 3
BR−30
BRAKE SYSTEM − REAR BRAKE 2WD

REAR BRAKE 2WD

COMPONENTS

REAR BRAKE 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 easily removed, perform
the following steps.
(a) Insert a screwdriver through the hole in the backing plate,
and hold the automatic adjusting lever away from the
adjusting bolt.
(b) Using another screwdriver, reduce the brake shoe
adjustment by turning the adjusting bolt.
 BR−31
BRAKE SYSTEM − REAR BRAKE 2WD

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 remove
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.

(c) Remove the adjuster together with the return spring.

(d) Using pliers, disconnect the parking brake cable from the
lever and remove the rear shoe.

6. 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.

7. DISCONNECT BRAKE LINE FROM WHEEL CYLINDER

Using SST, disconnect the brake line. Use a container to
catch the brake fluid.
SST 09751−36011
8. REMOVE WHEEL CYLINDER
Remove the 2 bolts and wheel cylinder.
BR−32
BRAKE SYSTEM − REAR BRAKE 2WD

9. REMOVE FOLLOWING PARTS FROM WHEEL CYLINDER

(a) 2 boots
(b) 2 pistons
(c) 2 piston cups
(d) Spring

REAR BRAKE COMPONENTS

INSPECTION AND REPAIR
1. INSPECT DISASSEMBLED PARTS
Inspect the disassembled parts for wear, rust or damage.

2. MEASURE BRAKE DRUM INSIDE DIAMETER

Standard inside diameter:
254.0 mm (10.00 in.)
Maximum inside diameter:
256.0 mm (10.08 in.)
If the drum is scored or worn, the brake drum may be lathed
to the maximum inside diameter.

3. MEASURE BRAKE SHOE LINING THICKNESS

Standard thickness:
5.0 mm (0.197 in.)
Minimum thickness:
1.0 mm (0.039 in.)
If the shoe lining is less than minimum or shows signs of un-
even, wear, replace the brake shoes.
HINT: If any of the brake shoes have to be replaced, replace
all of the 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,
repair the lining with a brake shoe grinder, or replace the
brake shoe assembly.
 BR−33
BRAKE SYSTEM − REAR BRAKE 2WD

REAR BRAKE INSTALLATION

HINT: Assemble the parts in the correct direction, as shown.

1. APPLY LITHIUM SOAP BASE GLYCOL GREASE TO

FOLLOWING PARTS:
(a) 2 piston cups
(b) 2 pistons
(c) 2 boots

2. ASSEMBLE WHEEL CYLINDER

(a) Install the spring and 2 piston cups into the wheel cylinder.
Check that the flanges of the piston cups are pointed inward.
(b) Install the 2 pistons.
(c) Install the 2 boots.
3. INSTALL WHEEL CYLINDER
Install the wheel cylinder on the backing plate with the 2 bolts.
Torque: 10 N⋅m (100 kgf⋅cm, 7 ft⋅lbf)
BR−34
BRAKE SYSTEM − REAR BRAKE 2WD

4. CONNECT BRAKE LINE TO WHEEL CYLINDER

Using SST, connect the brake line.
SST 09751−36011
Torque: 15 N⋅m (155 kgf⋅cm, 11 ft⋅lbf)

5. APPLY HIGH TEMPERATURE GREASE TO FOLLOWING

PARTS:
(a) Backing plate and brake shoe contact points
(b) Anchor plate and brake shoe contact points

(c) Adjusting bolt

(d) Adjuster and brake shoe contact points

6. INSTALL PARKING BRAKE LEVER AND AUTOMATIC

ADJUSTING LEVER
(a) Install the parking brake lever with a new C−washer.
(b) Install the automatic adjusting lever with the E−ring.

7. INSTALL ADJUSTER AND REAR SHOE

NOTICE: Do not allow oil or grease to get on the rubbing
face.
(a) Using pliers, connect the parking brake cable to the lever.
 BR−35
BRAKE SYSTEM − REAR BRAKE 2WD

(b) Set the adjuster and return spring.

(c) Install the adjusting lever spring.

(d) Set the rear shoe in place with the end of the shoe inserted
in the wheel cylinder and the other end in the anchor plate.
(e) Using SST, install the shoe hold−down spring, cups and pin.
SST 09718−00010

8. INSTALL FRONT SHOE

NOTICE: Do not allow oil or grease to get on the rubbing
face.
(a) Install the anchor spring between the front and rear shoes.
(b) Set the front shoe in place with the end of the shoe inserted
in the wheel cylinder and the adjuster in place.

(c) Using SST, install the shoe hold−down spring, cups and pin.
SST 09718−00010
(d) Using SST, connect the return spring.
SST 09703−30010

9. 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.
BR−36
BRAKE SYSTEM − REAR BRAKE 2WD

(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.

10. 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:
0.6 mm (0.024 in.)
If incorrect, check the parking brake system.
11. INSTALL BRAKE DRUM AND REAR WHEEL
12. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND
BLEED BRAKE SYSTEM
(See page BR−9)
13. CHECK FOR FLUID LEAKAGE
 BR−87
BRAKE SYSTEM − SERVICE SPECIFICATIONS

SERVICE SPECIFICATIONS
SERVICE DATA
ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑ
Brake pedal height 2WD 148 mm (5.83 in.)

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑ
4WD 145 mm (5.71 in.)

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑ
Brake pedal freeplay 3−6 mm (0.12−0.24 in.)

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑ
Brake pedal reserve distance at 490 N (50 kgf, 110.2 lbf)

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
2WD
ÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑ 22R−E Engine More than 70 mm (2.76 in.)

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑ 3VZ−E Engine More than 65mm (2.56 in.)

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
4WD
ÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑ
Brake booster push rod to piston clearance (w/SST)
More than 65 mm (2.56 in.)
0 mm (0 in.)

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑ
Front brake pad thickness

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑ
2WD USA STD model
ÑÑÑÑÑÑÑÑÑÑÑÑÑ STD 9.5 mm (0.374 in.)

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑ
2WD EX. USA STD model
ÑÑÑÑÑÑÑÑÑÑÑÑÑ
Limit
STD
1.0 mm (0.039 in.)
10.0 mm (0.394 in.)

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑ
Limit 1.0 mm (0.039 in.)

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑ
4WD STD 9.5 mm (0.374 in.)

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑ
Limit 1.0 mm (0.039 in.)

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑ
Front brake disc thickness

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑ
2WD STD 22.0 mm (0.866 in.)

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑ Limit 20.0 mm (0.787 in.)

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
4WD
ÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑ STD 20.0 mm (0.787 in.)

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑ
Front brake disc runout
Limit 18.0 mm (0.709 in.)

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
2WD
ÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
4WD
ÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑ
Limit
Limit
0.09 mm (0.0035 in.)
0.09 mm (0.0035 in.)

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
2WD
ÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑ
Rear brake drum inside diameter

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑ STD 254.0 mm (10.000 in.)

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑ
Limit 256.0 mm (10.079 in.)

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑ
4WD STD 295.0 mm (11.614 in.)

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑ
Limit 297.0 mm (11.693 in.)

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑ
Rear brake lining thickness

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑ
2WD STD 5.0 mm (0.197 in.)

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑ Limit 1.0 mm (0.039 in.)

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
4WD
ÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑ STD 6.0 mm (0.236 in.)

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑ Limit 1.0 mm (0.039 in.)

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑ
Rear brake drum to shoe clearance 0.6 mm (0.024 in.)

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
2WD
ÑÑÑÑÑÑÑÑÑÑÑÑÑ
Parking brake lever travel at 196 N (20 kgf, 44 lbf)

ÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑ 12−18 clicks

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
4WD
ÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑ 11−17 clicks
BR−88
BRAKE SYSTEM − SERVICE SPECIFICATIONS

TORQUE SPECIFICATIONS
ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑ
ÑÑÑÑÑ ÑÑÑÑÑÑ
Part tightened

ÑÑÑÑÑÑ
ÑÑÑÑÑÑ
Master cylinder X Piston stopper bolt
N⋅m
10
kgf⋅cm
100
ft⋅lbf
7

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑ
ÑÑÑÑÑ ÑÑÑÑÑÑ
ÑÑÑÑÑÑ
Master cylinder X Reservoir
ÑÑÑÑÑÑ
1.7 17.5 15.2 in.⋅lbf

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑ
Master cylinder X Brake booster 13 130 9

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
Brake line union nut
ÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑ
ÑÑÑÑÑ ÑÑÑÑÑÑ
ÑÑÑÑÑÑ
Brake booster clevis lock nut
ÑÑÑÑÑÑ
15
25
155
260
11
19

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑ
Brake booster X Pedal bracket 13 130 9

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑ
Front disc brake caliper sliding pin 2WD 88 900 65

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑ
ÑÑÑÑÑ ÑÑÑÑÑÑ
Torque plate X Steering knuckle

ÑÑÑÑÑÑ
ÑÑÑÑÑÑ
2WD 108 1,100 80

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑ
Front brake caliper X Steering knuckle 4WD 123 1,250 90

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑ
Rear brake wheel cylinder X Backing plate 10 100 7

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑ Duo−servo type 14 145 10

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
Bleeder plug
ÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑ 11 110 8

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑ
LSP & BV (LSPV) bracket X Frame 19 195 14

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑ
LSP & BV (LSPV) X LSP & BV (LSPV) bracket 13 130 9

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑ
LSP & BV (LSPV) spring X LSP & BV (LSPV) bracket 18 185 13

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑ
LSP & BV (LSPV) spring X Shackle 18 185 13

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑ
LSP & BV (LSPV) shackle lock nut 25 250 18

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑ
ÑÑÑÑÑ ÑÑÑÑÑÑ
LSP & BV (LSPV) shackle X Shackle bracket

ÑÑÑÑÑÑ
ÑÑÑÑÑÑ
LSP & BV (LSPV) shackle bracket X Rear axle housing
13
19
130
195
9
14

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑ
ABS actuator X PS pressure line 47 475 34

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑ
ABS actuator X ABS actuator bracket 13 130 9

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑ
ABS actuator bracket X Frame

ÑÑÑÑÑ ÑÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑ
Speed sensor installation bolt
28
19
290
195
21
14
ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑ
ÑÑÑÑÑ ÑÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑ
Speed sensor wire harness X Clamp bracket 19 195 14

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑ
Clamp bracket X Rear differential 19 195 14

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑ
ÑÑÑÑÑÑ
Deceleration sensor X Body
ÑÑÑÑÑÑ 5.4 55 48 in.⋅lbf

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑ
ÑÑÑÑÑÑ
ÑÑÑÑÑÑ
 TROUBLESHOOTING
BR−6
cause of the problem. Check each part in order. If necessary, replace these parts.
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
Low pedal or spongy pedal
Brake pull
Hard pedal but brake inefficient
Noise from brakes

Brake drag

Part Name

See page
Trouble

BRAKE SYSTEM
Brake system (Fluid leaks)
Brake system (Air in)
BR−18, BR−24,
Brake pad or lining (Worn) BR−30, BR−37
BR−18, BR−24
Piston seal (Worn or damaged)
BR−7
Brake pedal (Freeplay minimal)

−
BR−11
Master cylinder (Faulty)

TROUBLESHOOTING
BR−30, BR−37
Rear brake (Shoe clearance out of adjustment)
BR−10
Parking brake (Lever travel out of adjustment)
Parking brake wire (Sticking)
BR−17
Booster push rod (Out of adjustment)
BR−30, BR−37
Anchor or return spring (Faulty)
BR−18, BR−24,
Pad or lining (Cracked or distorted) BR−30, BR−37
BR−18, BR−24,
Piston (Stuck) BR−30, BR−37
BR−18, BR−24,
Pad or lining (oily) BR−30, BR−37
BR−18, BR−24,
Piston (Frozen) BR−30, BR−37

Booster system (Vacuum leaks) BR−9

BR−18, BR−24
Pad support plate (Loose)
BR−18, BR−24,
Installation bolt (Loose) BR−30, BR−37
BR−18, BR−24
Sliding in (Worn)
BR−18, BR−24
Rotor (Scored)
BR−18, BR−24,
Pad or lining (Dirty) BR−30, BR−37
BR−18, BR−24,
Pad or lining (Hardened) BR−30, BR−37
BR−18, BR−24
Anti−squeal shim (Damaged)
BR−30, BR−37
Hold−down spring (Damaged)