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Specified Condition
LHD
(M/T)
LHD
(A/T)
RHD
(M/T)
RHD
(A/T)
iii.
iv.
v.
vi.
Insert the switch into the adjuster until it slightly touches the pedal.
NOTICE:
Do not depress the pedal.
vii.
viii.
ix.
a. Stop the engine. Depress the pedal several times until there is no vacuum in the
booster. Then release the pedal.
b. Depress the pedal until resistance is felt.
c. Check the pedal's free play by measuring the distance between the position in the
previous step and the pedal's released position.
Pedal free play:
1.0 to 6.0 mm (0.039 to 0.236 in.)
If the free play is not as specified, check the switch clearance in the next step.
If the free play is as specified, proceed to the "check brake pedal reserve
distance" procedure.
d. Check the switch clearance.
Stop light switch clearance:
1.5 to 2.5 mm (0.059 to 0.098 in.)
If the clearance is not as specified, adjust the clearance and recheck the pedal's
free play.
If the clearance is as specified, troubleshoot the brake system and proceed to
the "check brake pedal reserve distance" procedure.
Depress the pedal with a force of 490 N (50 kgf, 110 lbf).
Measure the distance between the pedal and dash panel shown in the
illustration.
Pedal reserve distance:
Model
Specified
Condition
LHD (2WD)
78.0 mm
(3.071 in.)
LHD (4WD)
85.0 mm
(3.347 in.)
RHD (2WD)
82.0 mm
(3.228 in.)
89.0 mm
(3.504 in.)
NOTICE:
Release the vacuum from the booster by depressing the brake pedal several
times. Then remove the brake master cylinder sub-assembly from the brake
booster assembly.
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION:
Wait at least 90 seconds after disconnecting the cable from the negative (-)
battery terminal to prevent airbag and seat belt pretensioner activation.
NOTICE:
When disconnecting the cable, some systems need to be initialized after the
cable is reconnected (Click here).
The brake booster interior must not be a vacuum when adjusting the booster.
Stop the engine and depress the brake pedal several times until there is no
vacuum in the booster.
HINT:
Adjust the booster push rod when the master cylinder is replaced with a new
one. Adjustment is not necessary when the master cylinder is reinstalled and
the booster is replaced with a new one.
a. Set SST on the master cylinder, and then lower the pin until its tip slightly
touches the piston.
SST
09737-00013
HINT:
SST 09797-00012 can also be used.
a. Airtightness check.
i.
ii.
iii.
iv.
Start the engine and stop it after 1 or 2 minutes. Depress the brake pedal
several times.
Make sure the booster is airtight. Check that the distance the pedal can be
depressed decreases gradually in correlation with each subsequent press of
the pedal.
If the pedal is not as specified, check the check valve.
If the check valve is normal, replace the booster.
Start the engine. Depress and hold down the pedal, and stop the engine.
Make sure the booster is airtight. Hold the pedal for 30 seconds and check that
there is no change in the pedal reserve distance.
If the pedal is not as specified, check the check valve.
If the check valve is normal, replace the booster.
b. Operation check.
i.
ii.
Depress the pedal several times with the ignition switch OFF and check that
there is no change in the pedal reserve distance.
Depress and hold down the pedal, and start the engine. Check that the pedal
can only be depressed slightly.
If the pedal is not as specified, check the check valve.
If the check valve is normal, replace the booster.
a. Check that air flows from the hose side to the pump side.
b. Check that air does not flow from the pump side to the hose side.
If necessary, replace the check valve sub-assembly.
HINT:
a. Using a union nut wrench, disconnect the tube from the cylinder.
a. Remove the hole plug (check), and check the shoe lining thickness through the
hole.
Minimum thickness:
1.0 mm (0.039 in.)
If the thickness is less than the minimum, replace the shoe.
HINT:
If the drum cannot be removed easily, perform the following procedures.
b. Remove the hole plug (adjust) and insert a screwdriver into the hole on the
backing plate, and hold the automatic adjust lever away from the adjuster.
c. Using another screwdriver, compress the brake shoe adjuster by turning the
adjusting wheel.
a. Using a drum gauge or equivalent, measure the inside diameter of the drum.
Standard inside diameter:
254.0 mm (10.000 in.)
Maximum inside diameter:
256.0 mm (10.079 in.)
If the inside diameter of the drum is greater than the maximum, replace the
drum.
3. CHECK BRAKE DRUM AND BRAKE SHOE LINING FOR PROPER CONTACT
a. Apply chalk to the inside surface of the drum. Then grind the brake shoe lining on
the drum until full contact is achieved.
If the drum and brake shoe lining do not have full contact, use a brake shoe
grinder or replace the brake shoe.
b. After the inspection, wipe chalk off of the inside surface of the drum and lining
surface.
a. Using SST, disconnect the 3 brake lines from the valve body.
SST
09023-00101
b. Remove the 3 bolts and valve
Fluid:
SAE J1703 or FMVSS No. 116 DOT3
Fluid:
SAE J1703 or FMVSS No. 116 DOT3
Fluid:
SAE J1703 or FMVSS No. 116 DOT3
Fluid:
SAE J1703 or FMVSS No. 116 DOT3
7. BLEED AIR FROM BRAKE MASTER CYLINDER (for TMT Made LHD)
HINT:
If the master cylinder has been disassembled or if the reservoir becomes
empty, bleed air from the master cylinder.
a. Using SST, disconnect the 2 brake lines from the master cylinder.
SST
09023-00101
b. Slowly depress and hold the brake pedal.
c. Cover the outer holes with your finger, and release the pedal.
d. Repeat the 2 previous steps 3 or 4 times.
e. Using SST, connect the 2 brake lines to the master cylinder.
SST
09023-00101
Torque:
15.2 N*m{ 155 kgf*cm , 11 ft.*lbf } without SST
14 N*m{ 143 kgf*cm , 10 ft.*lbf } with SST
HINT:
Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
8. BLEED AIR FROM BRAKE MASTER CYLINDER (for TMT Made RHD)
HINT:
If the master cylinder has been disassembled or if the reservoir becomes
empty, bleed air from the master cylinder.
a. Using SST, disconnect the 2 brake lines from the master cylinder.
SST
09023-00101
b. Slowly depress and hold the brake pedal.
c. Cover the outer holes with your finger, and release the pedal.
d. Repeat the 2 previous steps 3 or 4 times.
e. Using SST, connect the 2 brake lines to the master cylinder.
SST
09023-00101
Torque:
15.2 N*m{ 155 kgf*cm , 11 ft.*lbf } without SST
14 N*m{ 143 kgf*cm , 10 ft.*lbf } with SST
HINT:
Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
9. BLEED AIR FROM BRAKE MASTER CYLINDER (for TSAM Made LHD)
HINT:
If the master cylinder has been disassembled or if the reservoir becomes
empty, bleed air from the master cylinder.
a. Using SST, disconnect the 2 brake lines from the master cylinder.
SST
09023-00101
b. Slowly depress and hold the brake pedal.
c. Cover the outer holes with your finger, and release the pedal.
d. Repeat the 2 previous steps 3 or 4 times.
e. Using SST, connect the 2 brake lines to the master cylinder.
SST
09023-00101
Torque:
15.2 N*m{ 155 kgf*cm , 11 ft.*lbf } without SST
14 N*m{ 143 kgf*cm , 10 ft.*lbf } with SST
HINT:
Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
10. BLEED AIR FROM BRAKE MASTER CYLINDER (for TSAM Made RHD)
HINT:
If the master cylinder has been disassembled or if the reservoir becomes
empty, bleed air from the master cylinder.
a. Using SST, disconnect the 2 brake lines from the master cylinder.
SST
09023-00101
b. Slowly depress and hold the brake pedal.
c. Cover the outer holes with your finger, and release the pedal.
d. Repeat the 2 previous steps 3 or 4 times.
e. Using SST, connect the 2 brake lines to the master cylinder.
SST
09023-00101
Torque:
15.2 N*m{ 155 kgf*cm , 11 ft.*lbf } without SST
14 N*m{ 143 kgf*cm , 10 ft.*lbf } with SST
HINT:
Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
11. BLEED AIR FROM LOAD SENSING VALVE BODY (for TSAM Made LHD)
a. Remove the bleeder plug cap.
Torque:
10.5 N*m{ 107 kgf*cm , 8 ft.*lbf }
g. Install the bleeder plug cap.
12. BLEED AIR FROM LOAD SENSING VALVE BODY (for TSAM Made RHD)
a. Remove the bleeder plug cap.
Torque:
10.5 N*m{ 107 kgf*cm , 8 ft.*lbf }
g. Install the bleeder plug cap.
13. REMOVE AIR FROM LOAD SENSING VALVE BODY (for TMT Made LHD)
a. Remove the bleeder plug cap.
Torque:
10.5 N*m{ 107 kgf*cm , 8 ft.*lbf }
g. Install the bleeder plug cap.
14. REMOVE AIR FROM LOAD SENSING VALVE BODY (for TMT Made RHD)
a. Remove the bleeder plug cap.
Torque:
10.5 N*m{ 107 kgf*cm , 8 ft.*lbf }
g. Install the bleeder plug cap.
15. BLEED AIR FROM BRAKE LINE (for TMT Made LHD)
a. Remove the bleeder plug cap.
b. Connect the vinyl tube to the bleeder plugs.
c. Depress the pedal several times, and then loosen the bleeder plug
with the pedal depressed.
d. When fluid stops coming out, immediately tighten the bleeder plug.
Then release the pedal.
e. Repeat the 2 previous steps until all the air in the brake fluid is
gone.
f.
Torque:
10.8 N*m{ 110 kgf*cm , 8 ft.*lbf } for front brake
11 N*m{ 112 kgf*cm , 8 ft.*lbf } for rear brake (2WD)
10 N*m{ 102 kgf*cm , 7 ft.*lbf } for rear brake (4WD)
g. Install the cap.
h. Bleed air from the brake line for each wheel by repeating the above
procedures.
16. BLEED AIR FROM BRAKE LINE (for TMT Made RHD)
a. Remove the bleeder plug cap.
b. Connect the vinyl tube to the bleeder plugs.
c. Depress the pedal several times, and then loosen the bleeder plug
with the pedal depressed.
d. When fluid stops coming out, immediately tighten the bleeder plug.
Then release the pedal.
e. Repeat the 2 previous steps until all the air in the brake fluid is
gone.
f.
Torque:
10.8 N*m{ 110 kgf*cm , 8 ft.*lbf } for front brake
11 N*m{ 112 kgf*cm , 8 ft.*lbf } for rear brake (2WD)
10 N*m{ 102 kgf*cm , 7 ft.*lbf } for rear brake (4WD)
g. Install the cap.
h. Bleed air from the brake line for each wheel by repeating the above
procedures.
17. BLEED AIR FROM BRAKE LINE (for TSAM Made LHD)
a. Remove the bleeder plug cap.
b. Connect the vinyl tube to the bleeder plugs.
c. Depress the pedal several times, and then loosen the bleeder plug
with the pedal depressed.
d. When fluid stops coming out, immediately tighten the bleeder plug.
Then release the pedal.
e. Repeat the 2 previous steps until all the air in the brake fluid is
gone.
f.
Torque:
10.8 N*m{ 110 kgf*cm , 8 ft.*lbf } for front brake
11 N*m{ 112 kgf*cm , 8 ft.*lbf } for rear brake (2WD)
10 N*m{ 102 kgf*cm , 7 ft.*lbf } for rear brake (4WD)
g. Install the cap.
h. Bleed air from the brake line for each wheel by repeating the above
procedures.
18. BLEED AIR FROM BRAKE LINE (for TSAM Made RHD)
a. Remove the bleeder plug cap.
b. Connect the vinyl tube to the bleeder plugs.
c. Depress the pedal several times, and then loosen the bleeder plug
with the pedal depressed.
d. When fluid stops coming out, immediately tighten the bleeder plug.
Then release the pedal.
e. Repeat the 2 previous steps until all the air in the brake fluid is
gone.
f.
Torque:
10.8 N*m{ 110 kgf*cm , 8 ft.*lbf } for front brake
11 N*m{ 112 kgf*cm , 8 ft.*lbf } for rear brake (2WD)
10 N*m{ 102 kgf*cm , 7 ft.*lbf } for rear brake (4WD)
g. Install the cap.
h. Bleed air from the brake line for each wheel by repeating the above
procedures.
Torque:
11 N*m{ 112 kgf*cm , 8 ft.*lbf }
g. Install the bleeder plug cap.
h. Check that all the air has been bled out of the clutch line.
20. CHECK BRAKE FLUID LEVEL IN RESERVOIR (for TMT Made LHD)
21. CHECK BRAKE FLUID LEVEL IN RESERVOIR (for TMT Made RHD)
22. CHECK BRAKE FLUID LEVEL IN RESERVOIR (for TSAM Made LHD)
23. CHECK BRAKE FLUID LEVEL IN RESERVOIR (for TSAM Made RHD)
Specified Condition
2WD Single
Cab
2WD Double
Cab
4WD Single
Cab
4WD Double
Cab
10,297 N (1,050
kgf, 2,315 lbf)
Pre-runner
Single Cab
Pre-runner
Double Cab
10,297 N (1,050
kgf, 2,315 lbf)
NOTICE:
d. Raise the front brake fluid pressure to 10,000 kPa (107.6 kgf/cm 2,
1,450 psi) when the brake pedal is depressed, and measure the
rear brake fluid pressure.
Standard rear brake fluid pressure:
Vehicle
Type
Specified Condition
2WD
4WD and
4,450 +-490 kPa (45.4
Pre-runner +-5.0 kgf/cm2, 645 +-
71 psi)
HINT:
The pedal should not be depressed twice or released while the specified
pressure is being set. Read the value of the rear pressure after adjusting and
holding the specified fluid pressure for 2 seconds.
If necessary, adjust the load sensing proportioning valve.
120 mm (4.764
in.)
190 mm (7.543
in.)
Specified Condition
2WD
114 to 126 mm
(4.526 to 5.002 in.)
4WD and
Pre-runner
184 to 196 mm
(7.305 to 7.781 in.)
HINT:
The rear fluid pressure changes according to the table below by adjusting the
length of "A".
Vehicle Type
2WD