Brake System

BR–1
BRAKE SYSTEM –
BRAKE SYSTEM
BR–2
BRAKE SYSTEM – Precautions
PRECAUTIONS
1. Care must be taken to replace each part properly as it
could affect the performance of the brake system and re–
sult 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.
TROUBLESHOOTING
Problem Possible cause Remedy Page
Low or spongy pedal Linings worn Replace brake shoes BR–40, 47
Brake pads worn Replace pads 55
Leak in brake system Repair leak BR–18, 26
Master cylinder faulty Repair or replace master 33
Air in brake system cylinder BR–10
Wheel cylinder faulty Bleed brake system BR–8
Brake cylinder faulty Repair wheel cylinder BR–40, 47
Piston seals worn or damaged Repair cylinder 55
Rear brake automatic adjuster faulty Repair brake cylinder BR–18, 26
Repair or replace adjuster 33
BR–18, 26
33
BR–40, 47
55
Brakes drag Parking brake out of adjustment Adjust parking brake BR–9
Binding parking brake wire Repair as necessary BR–17
Booster push rod out of adjustment Adjust push rod BR–40, 47
Tension or return spring faulty Replace spring 55
Brake line restricted Repair as necessary BR–40, 47
Lining cracked or distorted Replace shoe 55
Pad cracked or distorted Replace pad BR–18, 26
Wheel cylinder or caliper piston sticking Repair as necessary 33
Adjuster broken Replace adjuster BR–18, 26
cylinder BR–10
Brakes pull Tires improperly inflated Inflate tires to proper pressure

Oil or grease on shoes or pads Check for cause. Replace shoes
Brake shoes distorted, linings worn or or pads
glazed Replace brake shoes BR–40, 47
Brake pads distorted, worn or glazed Replace pads 55
Drum or disc out of round Replace drum or disc BR–18, 26
33
BR–18, 26
33,40
47, 55
Replace spring BR–40, 47
Tension or return spring faulty
Repair wheel cylinder 55
Wheel cylinder faulty
Repair cylinder BR–18, 26
Brake cylinder faulty
Repair cylinder 33
Piston frozen in brake cylinder
Replace pads BR–18, 26
Brake pad sticking
33
BR–18, 26
33
BR–2
BRAKE SYSTEM – Precautions
PRECAUTIONS
1. Care must be taken to replace each part properly as it
could affect the performance of the brake system and re–
sult 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.
TROUBLESHOOTING
Low or spongy pedal Linings worn Replace brake shoes BR–40, 47
Brake pads worn Replace pads 55
Leak in brake system Repair leak BR–18, 26
Air in brake system cylinder BR–10
Wheel cylinder faulty Bleed brake system BR–8
Brake cylinder faulty Repair wheel cylinder BR–40, 47
Piston seals worn or damaged Repair cylinder 55
Rear brake automatic adjuster faulty Repair brake cylinder BR–18, 26
Repair or replace adjuster 33
BR–18, 26
33
BR–40, 47
55
Brakes drag Parking brake out of adjustment Adjust parking brake BR–9
Binding parking brake wire Repair as necessary BR–17
Booster push rod out of adjustment Adjust push rod BR–40, 47
Tension or return spring faulty Replace spring 55
Brake line restricted Repair as necessary BR–40, 47
Lining cracked or distorted Replace shoe 55
Pad cracked or distorted Replace pad BR–18, 26
Wheel cylinder or caliper piston sticking Repair as necessary 33
Adjuster broken Replace adjuster BR–18, 26
cylinder BR–10
Brakes pull Tires improperly inflated Inflate tires to proper pressure

Oil or grease on shoes or pads Check for cause. Replace shoes
Brake shoes distorted, linings worn or or pads
glazed Replace brake shoes BR–40, 47
Brake pads distorted, worn or glazed Replace pads 55
Drum or disc out of round Replace drum or disc BR–18, 26
33
BR–18, 26
33,40
47, 55
Replace spring BR–40, 47
Tension or return spring faulty
Repair wheel cylinder 55
Wheel cylinder faulty
Repair cylinder BR–18, 26
Brake cylinder faulty
Repair cylinder 33
Piston frozen in brake cylinder
Replace pads BR–18, 26
Brake pad sticking
33
BR–18, 26
33
BR–3
BRAKE SYSTEM – Troubleshooting
TROUBLESHOOTING (Cont’d)
Hard pedal but Oil or grease on shoes or pads Check for cause. Replace
brakes inefficient shoes or pads
Replace brake shoes
Brake shoes distorted, linings worn or Replace pads BR–40, 47
glazed, drums worn 55
Brake pads distorted, worn or glazed BR–18, 26
33
BR–18, 26
33
Piston frozen in brake cylinder Repair cylinder BR–16
Brake booster faulty Repair booster

Vacuum leaks Repair as necessary
Brake line restricted Repair as necessary
Snapping or clicking (Drum brake)

noise when brakes Brake shoes binding at backing plate BR–40, 47
Lubricate
are applied ledges
55
Backing plate ledges worn BR–40, 47
Replace and lubricate ledges 55
BR–40, 47
55
Loose or missing shoe hold–down spring Replace shoe hold–down spring BR–40, 47
55
Loose set bolt at backing plate Tighten
(Disc brake)
Loose or missing pad support plate Replace pad support plate BR–18, 26
33
BR–18, 26
Loose installation bolt Tighten 33
Scraping or grinding Worn brake linings or pads Replace or refinish drums or BR–18, 26
noise when brakes rotors if heavily scored 33,40
are applied 47, 55
BR–18, 26
Caliper to wheel or rotor interference Replace as required 33
BR–18, 26
33,40
Dust cover to rotor or backing plate to Correct or replace 47, 55
drum interference
Other brake system components faulty Repair or replace as necessary

Tires rubbing against chassis and/or body Repair as necessary
BR–4
Squeaking, squealing Brake drums and linings, rotors and pads Inspect, repair or replace BR–18, 26
groaning or worn or scored 33,40
chattering noise Dirty, greased, contaminated or glazed 47, 55
when brakes are linings or pads BR–18, 26
applied Improper linings or pads using Clean or replace
33,40
MaIadjustment of brake pedal or booster 47, 55
HINT: Brake friction push rod
materials inherently (Disc brake)
generate noise and Inspect for correct usage or
Missing or damaged brake pad anti–squeal replace
heat in order to shim
dissipate energy. As Inspect and adjust
Pad wear and pad wear indicator making BR–6,
a result, occasional
squeal is normal and contact with the rotor 17
is aggravated by Burred or rusted calipers
severe environmental (Drum brake)
conditions such as Weak damaged or incorrect shoe hold– Replace BR–1
cold, heat, wetness, down springs, loose or damaged shoe Replace 8, 26
snow, salt, mud, etc. hold–down spring pins and springs and Clean or deburr
This occasional 33
grooved backing plate ledges BR–18, 26
squeal is not a
functional problem 33
and does not indicate BR–18, 26
any loss of brake
effectiveness 33
Inspect, repair or replace
BR–40, 47
55
Squealing and MaI–adjustment of brake pedal or booster Inspect and adjust BR–6, 17
squeaking noise push rod Inspect, repair or replace BR–10, 16
when brakes are not Poor return of brake booster or master 18,26
applied cylinder or brake cylinder 33,40
47, 55
(Disc brake)
Rusted or stuck piston Inspect and lubricate as BR–18, 26
Improper positioning of pad in caliper necessary 33
Rotor rubbing against caliper housing Reinstall correctly
Improper installation of disc brake pad Inspect and replace
support plate Reinstall correctly
Pad wear and pad wear indicator making Replace
contact with the rotor BR–18, 2
(Drum brake) 33
Weak, damaged or incorrect shoe hold– BR–18, 26
down springs 33
Grooved backing plate ledges
Bent or warped backing plate causing
interference with drum Replace BR–40, 47
Improper machining of drum causing Repair or replace 55
interference with backing plate or shoe Repair or replace BR–40, 47
Other brake system components: Replace drum 55
Loose or extra parts in brakes Inspect, repair or replace as BR–40, 47
Rear drum adjustment too tight necessary
causing lining to glaze 55
Worn, damaged or insufficiently BR–40, 47
lubricated wheel bearings 55
BR–40, 47
55
BR–5
Groaning, clicking or Stones or foreign material trapped inside Remove foreign material
rattling noise when wheel covers
brakes are not Loose wheel nuts
applied Tighten to correct torque
Replace if stud holes are
elongated
Inspect and adjust
MaI–adjustment of brake pedal or booster BR–6, 17
push rod
Worn, damaged or dry wheel bearings
(Disc brake) Inspect and lubricate or replace
Loose or missing anti–rattle spring or pad
support plate or crimping on outer pad
Failure of shim Inspect, repair or replace BR–18, 26
33
BR–18, 26
Inspect, replace if necessary 33
BR–18, 26
Wear on slide bushing Inspect, replace if necessary
33
BR–18, 26
Loose installation bolt Inspect, tighten if necessary 33
BR–18, 26
Poor return of piston Inspect, repair or replace 33
(Drum brake)
Loose or extra parts
Inspect and repair BR–40, 47
55
BR–6
BRAKE SYSTEM – Checks and Adjustments
CHECKS AND ADJUSTMENTS

CHECK AND ADJUSTMENT OF BRAKE PEDAL
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) Return the stop light switch one turn.
(f) Check the clearance
(A) between stop light switch
and pedal.
Clearance: 0.5 – 2.4mm (0.02 – 0.09 in.)
(i) Tighten the stop light switch lock nut.
(j) Check that the stop light 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.
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.
(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 – 6mm (0.12 – 0.24 in.)
(Tandem booster)
HINT: The freeplay to the first resistance is due to the
play between the clevis and pin. And it is 1 – 3mm (0.04
– 0.12 in.) on the pedal.
BR–7
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
1 ton More than 75 mm (2.95 in.)
1/2 ton More than 65 mm (2.56 in.)
C&C
SRW More than 75 mm (2.95 in.)
DRW More than 55 mm (2.17 in.)
(4WD) More than 65 mm (2.56 in.)
If incorrect, troubleshoot the brake system.
OPERATIONAL TEST OF BRAKE BOOSTER

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 en–
gine 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 one or two min–
utes. Depress the brake pedal several times slowly.
If the pedal goes down deepest the first time, but
gradually rises after the second or third 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 thirty seconds, the booster is air tight.
BR–8
BLEEDING OF BRAKE SYSTEM

HINT: If any work is done on the brake system or if air is
suspected 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
reservoir tank becomes empty, bleed the air from the
master cylinder.
(a) Disconnect the brake tubes 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) three or four times.
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

BR–9
CHECK AND ADJUSTMENT OF PARKING BRAKE

1. CHECK THAT PARKING BRAKE LEVER TRAVEL IS
CORRECT
Pull the parking brake lever all the way up, and count the
number of clicks.
Parking brake lever travel at 196 N (20 kgf, 44.1 lbf)
2WD 1/2 ton 12 – 18 clicks
1 ton 11 – 17 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 two adjusting nuts.
(b) After adjusting the parking brake, confirm that the
bellcrank stopper screw comes in contact with the
backing plate.
BR–10
BRAKE SYSTEM – Master Cylinder
MASTER CYLINDER
REMOVAL OF MASTER CYLINDER
1. DISCONNECT LEVEL WARNING SWITCH CONNECTOR

2. DRAW OUT FLUID WITH SYRINGE
NOTICE: Do not let brake fluid remain on a painted sur–
face. Wash it off immediately.
3. DISCONNECT BRAKE TUBES
Using SST, disconnect the brake tubes from the master
cylinder.
SST 09751–36011
4. REMOVE MASTER CYLINDER

(a) Remove the four nuts and 3–way union.
(b) Remove the clamp.
(c) Remove the master cylinder and gasket from the
brake booster.
BR–11
COMPONENTS
DISASSEMBLY OF MASTER CYLINDER

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 TWO GROMMETS
4. PLACE CYLINDER IN VISE

BR–12
5. 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.
6. REMOVE TWO 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 possibility of
damaging the cylinder bore.
(c) Place a rag and two 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.).
INSPECTION OF MASTER CYLINDER

COMPONENTS
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.
BR–13
ASSEMBLY OF MASTER CYLINDER
(See page BR–11)
1. APPLY LITHIUM SOAP BASE GLYCOL GREASE TO RUB–
BER PARTS INDICATED BY ARROWS
2. INSTALL TWO SPRINGS AND PISTONS

NOTICE: Be careful not to damage the rubber lips on
the pistons.
(a) Insert the two 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 the gasket. Torque the
bolt.
4. INSTALL TWO 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. –Ibf )
BR–14
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
INSTALLATION OF MASTER CYLINDER

(See page BR–10)
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 four nuts.
Torque: 13 N–m (130 kgf–cm, 9 ft–Ibf)
3. CONNECT TWO BRAKE TUBES

Using SST, connect the brake tubes to the master cylin–
der. Torque the union nuts.
SST 09751–36011
4. CONNECT LEVEL WARNING SWITCH CONNECTOR

5. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND
BLEED BRAKE SYSTEM
(See page BR–8)
6. CHECK FOR FLUID LEAKAGE
7. CHECK AND ADJUST BRAKE PEDAL
(See page BR–6)
BR–16
BRAKE SYSTEM – Brake Booster
BRAKE BOOSTER
REMOVAL OF BRAKE BOOSTER
1. REMOVE MASTER CYLINDER

(See page BR–10)
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
INSTALLATION OF BRAKE BOOSTER

(See page BR–16)
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 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–15)
6. CONNECT HOSE TO BRAKE BOOSTER

BLEED BRAKE SYSTEM
(See page BR–8)
9. CHECK AND ADJUST BRAKE PEDAL

(See page BR–6)
10. PERFORM OPERATIONAL CHECK

(See page BR–7)
BR–18
BRAKE SYSTEM – Front Brake – 2WD (PD60 66 Type Disc)
FRONT BRAKE
2WD (PD60 66 Type Disc)
COMPONENTS
REPLACEMENT OF BRAKE PADS

HINT: If a squealing noise occurs from the front brakes
while driving, check the pad wear indicator. If there are
traces of the indicator contacting the rotor disc, the
brake pad should be replaced.
1. REMOVE FRONT WHEEL
2. INSPECT PAD LINING THICKNESS

Check the pad thickness through the cylinder inspection
hole and replace pads if not within specification.
Minimum thickness: 1.0 mm (0.039 in.)
BR–19
BRAKE SYSTEM – Front Brake – 2WD (PD60, 66 Type Disc)
3. LIFT UP CYLINDER
(a) Remove the installation bolt from the torque plate.
(b) Lift up the brake cylinder and suspend it so the hose

is not stretched.
HINT: Do not disconnect the brake hose.
4. REMOVE FOLLOWING PARTS:

(a) Two anti–squeal springs
(b) Two brake pads
(c) Two anti–squeal shims
(d) Two pad wear indicator plates
(e) Four pad support plates
5. CHECK ROTOR DISC THICKNESS

(See step 2 on page BR–23)
6. CHECK ROTOR DISC RUNOUT
7. INSTALL PAD SUPPORT PLATES

BR–20
8. INSTALL NEW PADS

(a) Install a pad wear indicator plate to the pad.
(b) (PD60 Type)
Install the outside anti–squeal shim to the outside
pad.
(PD66 Type)
Install the two anti–squeal shims to the each pad.
(c) Install the two pads so the wear indicator plate is

facing underneath.
NOTICE: Do not allow oil or grease to get on the rub–
bing face.
(d) Install the anti–squeal springs in position.
9. INSTALL CYLINDER
(a) Draw out a small amount of brake fluid from the res–
ervoir.
(b) Press in piston with a hammer handle or an equiva–
lent.
HINT: Always change the pad on one wheel at a time as
there is a possibility of the opposite piston flying out.
(c) (PD60 Type)

Install the inside anti–squeal shim to the piston.
(d) Insert the brake cylinder carefully so the boot is not
wedged.
(e) Install and torque the installation bolts.

Torque: 39 N–m (400 kgf–cm, 29 ft –Ibf)
10. INSTALL FRONT WHEEL
11. CHECK THAT FLUID LEVEL IS MAX LINE

BR–21
REMOVAL OF CYLINDER
(See page BR–18)
1. DISCONNECT BRAKE TUBE
(a) Using SST, disconnect the brake tube. Use a con–
tainer to catch the brake fluid.
SST 09751–36011
(b) Remove the bracket from the cylinder.
2. REMOVE CYLINDER FROM TORQUE PLATE

Remove the two installation bolts and cylinder.
3. REMOVE PADS
BR–22
DISASSEMBLY OF CYLINDER
(See page BR–18)
1. (PD60 TYPE)
REMOVE CYLINDER SLIDING BUSHINGS, DUST
BOOTS AND COLLARS
(PD66 TYPE)
REMOVE CYLINDER SLIDING BUSHINGS AND DUST
BOOTS
(a) Remove the sliding bushings.
(b) Using a chisel and a hammer, remove the dust
boots.
2. REMOVE CYLINDER BOOT SET RING AND CYLINDER

BOOT
Using a screwdriver, remove the cylinder boot set ring
and cylinder boot.
3. REMOVE PISTON FROM CYLINDER

(a) Put a piece of cloth or an equivalent between the
piston and cylinder.
(b) Use compressed air to remove the piston from the
cylinder.
NOTICE: Do not place your fingers in front of the piston
when using compressed air.
4. REMOVE PISTON SEAL FROM BRAKE CYLINDER

Using a screwdriver, remove the piston seal.
BR–23
INSPECTION OF FRONT BRAKE COMPONENTS

1. MEASURE PAD LINING THICKNESS
Standard thickness:
PD60 Type 9.5 mm (0.374 in.)
PD66 Type 9.7 mm (0.382 in.)
Replace the pad if the thickness is less than the minimum
(the 1.0 mm slite is no longer visible), or if it shows sign
of uneven wear.
2. MEASURE ROTOR DISC THICKNESS

Standard thickness:
PD60 Type 25.0 mm (0.984 in.)
PD66 Type 30.0 mm (1.181 in.)
Minimum thickness:
PD60 Type 23.0 mm (0.906 in.)
PD66 Type 28.0 mm (1.102 in.)
If the disc is scored or worn, or if thickness is less than
minimum, repair or replace the disc.
3. MEASURE ROTOR DISC RUNOUT

HINT: Before measuring the runout, confirm that the
front hub bearing play is within specification.
Measure the rotor disc runout at 10 mm (0.39 in.) from
the outer edge of the rotor disc.
Maximum disc runout:
PD60 Type 0.09 mm (0.0035 in.)
PD66 Type 0.12 mm (0.0047 in.)
4. IF NECESSARY, REPLACE ROTOR DISC

(a) Remove the torque plate from the knuckle.
(b) Remove the axle hub. (See page SA–15)
(c) Remove the disc from the axle hub.
(d) Install a new rotor disc. Torque the bolts.
(e) Install the axle hub and adjust the front bearing
preload. (See page SA–16)
(f) Install the torque plate onto the knuckle.
Torque: 108 N–m (1,100 kgf–cm, 80 ft–lbf)
BR–24
ASSEMBLY OF CYLINDER
(See page BR–18)
1. APPLY LITHIUM SOAP BASE GLYCOL GREASE TO
PARTS INDICATED WITH ARROWS
2. INSTALL PISTON SEAL AND PISTON IN CYLINDER
3. INSTALL CYLINDER BOOT AND SET RING IN CYLINDER
4. (PD60 TYPE)
INSTALL COLLAR, DUST BOOTS AND CYLINDER
SLIDING BUSHINGS
(a) Install the collar and dust boots into the brake
cylinder.
(b) Insure that the boots is secured firmly to the brake
cylinder grooves.
(e) Install the bushing into the boots.
(d) Insure that the boots is secured firmly to the bush–
ing grooves.
(PD66 TYPE)
INSTALL DUST BOOTS AND CYLINDER SLIDING
BUSHINGS
(a) Using two socket wrenches and a vise, press in new
dust boots.
(b) Install the bushing into the boots.
(c) Insure that the boots is secured firmly to the bush–
ing grooves.
BR–25
INSTALLATION OF CYLINDER
(See page BR–18)
1. INSTALL PADS
(See steps 7 to 8 on pages BR–19 and 20)
2. INSTALL CYLINDER
(a) Insert the brake cylinder.
(b) Install and torque the two installation bolts.
Torque: 39 N–m (400 kgf –cm, 29 ft–Ibf)
3. INSTALL BRAKE TUBE TO BRAKE CYLINDER

(a) Install the bracket to the cylinder.
Torque: 18 N–m (185 kgf–cm, 13 ft–Ibf )
(b) Using SST, connect the brake tube to the cylinder.
SST 09751–36011

BLEED BRAKE SYSTEM
(See page BR–8)

BR–26
BRAKE SYSTEM – Front Brake – 2WD (FS17 18 Type Disc)
FRONT BRAKE
2WD (FS17 18 Type Disc)
COMPONENTS

HINT: If a squealing noise occurs from the front brakes
while driving, check the pad wear indicator. If there are
traces of the indicator contacting the rotor disc, the
brake pad should be replaced.

Check the pad thickness through the cylinder inspection
hole and replace pads if not within specification.
BR–27
BRAKE SYSTEM – Front Brake – 2WD (FS17, 18 Type Disc)
3. LIFT UP CYLINDER
(a) Remove the sliding sub pin from the torque plate.
(b) Lift up the brake cylinder and suspend it so the hose

is not stretched.
HINT: Do not disconnect the brake hose.

(a) Two brake pads
(b) Four anti–squeal shims
(c) Two pad wear indicator plates
(d) Four pad support plates

7. INSTALL PAD SUPPORT PLATES

BR–28
8. INSTALL NEW PADS

(a) Install a pad wear indicator plate to the pad.
(b) Install the two anti–squeal shims to the each pad.
HINT: Apply disc brake grease to both side of the inner
anti–squeal shim.
(C) Install the two pads so the wear indicator plate is

facing underneath.
bing face.
9. INSTALL CYLINDER
ervoir.
(b) Press in piston with a hammer handle or an equiva–
lent.
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 brake cylinder carefully so the boot is not
wedged.
(d) Install and torque the sliding sub pin.

11. CHECK THAT FLUID LEVEL IS MAX LINE

BR–29
REMOVAL OF CYLINDER
(See page BR–26)

SST 09751–36011
(b) Remove the bracket from the cylinder.
2. REMOVE CYLINDER FROM TORQUE PLATE

(a) Remove the sliding main pin and sliding sub pin.
(b) Remove the cylinder.
3. REMOVE PADS
(See page BR–26)
1. REMOVE PISTON FROM CYLINDER

(a) Put a piece of cloth or an equivalent between the
piston and cylinder.
(b) Use compressed air to remove the piston and cylin–
der boot from the cylinder.
CAUTION: Do not place your fingers in front of the pis–
ton when using compressed air.
2. REMOVE PISTON SEAL FROM BRAKE CYLINDER

Using a screwdriver, remove the piston seal.
BR–30
BRAKE SYSTEM – Front Brake – 2WD (FS17 18 Type Disc)
INSPECTION OF FRONT BRAKE

COMPONENTS
Standard thickness:
FS 17 Type 9.5 mm (0.374 in.)
FS18 Type 10.0 mm (0.394 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 sign of
uneven wear.

Standard thickness: 22.0 mm (0.866 in.)

front hub bearing play is within specification.
Maximum disc runout: 0.09 mm (0.0035 in.)

(a) Remove the torque plate from the knuckle.
(b) Remove the axle hub. (See page SA–15)
(c) Remove the disc from the axle hub.
(d) Install a new rotor disc. Torque the bolts.
(e) Install the axle hub and adjust the front bearing pre.
load. (See page SA–16)
(f) Install the torque plate onto the knuckle.
Torque: 108 N*m (1,100 kgf –cm, 80 ft–Ibf)
BR–31
(See page BR–26)
PARTS INDICATED WITH ARROWS
2. INSTALL PISTON SEAL IN CYLINDER
3. INSTALL PISTON AND CYLINDER BOOT IN CYLINDER
4. INSTALL PIN BOOT AND CYLINDER SLIDING BUSHING

(a) Install the pin boot into the sliding sub pin side.
(b) Using a plastic bar, install the cylinder sliding bush–
ing into the sliding sub pin side.
BR–32
(See page BR–26 )
1. INSTALL PADS
2. INSTALL CYLINDER
(a) Insert the brake cylinder.
(b) Install and torque the two sliding pins.
Torque: 88 N–m (900 kgf–cm, 65 ft–lbf )
3. CONNECT BRAKE TUBE

(a) Install the bracket to the cylinder.
Torque: 18 N–m (185 kgf –cm, 13 ft–lbf)
(b) Using SST, connect the brake tube to the cylinder.
SST 09751–36011

BLEED BRAKE SYSTEM
(See page BR–8)

BR–33
BRAKE SYSTEM – Front Brake – 4WD (S12 + 12 Type Disc)
FRONT BRAKE
4WD (S12 + 12 Type Disc)
COMPONENTS

HINT: If a squealing noise occurs from the brakes while
driving, check the pad wear indicator plate. If the pad
wear indicator plate contacts the rotor disc, the brake
pads should be replaced.

Check the pad thickness and replace pads if not within
specification.
BR–34
3. REMOVE FOLLOWING PARTS

(a) Clip
(b) Two pins
(c) Anti–rattle spring
(d) Two pads
(e) Four anti–squeal shims

6. INSTALL NEW PADS

ervoir.
(b) Press in the pistons with a hammer handle or ar
equivalent.
HINT: Always change the pads on one wheel at a time
as there is possibility of the opposite piston flying out.
(c) Install the four anti–squeal shims to new pads a:

shown.
HINT: Apply disc brake grease to both sides of the
inner anti–squeal shims.
(d) Install the two pads as shown in the illustration.
NOTICE: Do not allow oil or grease to get on the rub
bing face.
7. INSTALL ANTI–RATTLE SPRING

BR–35
8. INSTALL TWO PINS
9. INSTALL CLIP
REMOVAL OF CYLINDER
(See page BR–33)
Using SST, disconnect the brake tube.
Use a container to catch the brake fluid.
SST 09751–36011
3. REMOVE CYLINDER
Remove the two mounting bolts and remove the cylinder.

(a) Clip
(b) Two pins
(c) Anti–rattle spring
(d) Two pads
(e) Four anti–squeal shims
BR–36
(See page BR–33)
1. REMOVE CYLINDER BOOT SET RINGS AND BOOTS
Using a screwdriver, remove the four cylinder boot set
rings and four boots.
2. REMOVE PISTONS FROM CYLINDER

(a) Prepare the wooden plate as shown in the illustra–
tion to hold the pistons.
(b) Place the plate between the pistons and insert a pad
at one side.
(c) Use compressed air to remove the pistons alter–
nately from the cylinder.
NOTICE: Do not place your fingers in front of the pis–
tons when using compressed air.
3. REMOVE PISTON SEALS

Using a screwdriver, remove the four seals from the cyl–
inder.
BR–37
INSPECTION AND REPAIR OF FRONT BRAKE

COMPONENTS
Standard thickness: 9.5 mm (0. 374 in.)
Replace the pads if the thickness is less than the mini–
mum (the 1.5 mm slit is no longer visible) or if it shows
sign of uneven wear.


Maximum disc runout: 0.09 mm (0.0035 in.)
If the runout is greater than maximum, replace the rotor
disc.
front bearing play is within specification.

(a) Remove the front axle hub.
(b) Remove the disc from the axle hub.
(c) Install a new rotor disc and torque the bolts.

(d) Install the axle hub and adjust the front bearing pre–
load.
BR–38
(See page BR–33)
PARTS INDICATED BY ARROWS
2. INSTALL PISTON SEALS INTO CYLINDER
3. INSTALL PISTONS INTO CYLINDER
4. INSTALL CYLINDER BOOTS AND SET RINGS INTO

CYLINDER
BR–39
(See page BR–33)
1. INSTALL CYLINDER
Install the brake cylinder, and torque the two mounting
bolts.
Torque: 123 N–m (1,250 kgf–cm, 90 ft–lbf)
2. INSTALL PADS

Using SST, connect the brake tube.
SST 09751–36011

BLEED BRAKE SYSTEM
(See page BR–8)

BR–40
BRAKE SYSTEM – Rear Brake – 2WD (Leading–Trailing Type)
REAR BRAKE
2WD (Leading–Trailing Type)
COMPONENTS
REMOVAL OF REAR BRAKE

1. INSPECT SHOE LINING THICKNESS
Remove the inspection hole plug, and check the shoe lin–
ing thickness through the hole.
If less than minimum, replace the shoes.
2. REMOVE REAR WHEEL
3. REMOVE BRAKE DRUM

HINT: If the brake drum cannot be easily removed, per–
form 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–41
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 TUBE FROM WHEEL CYLINDER

Using SST, disconnect the brake tube. Use a container to
catch the brake fluid.
SST 09751–36011
8. REMOVE WHEEL CYLINDER

Remove the two bolts and wheel cylinder.
BR–42
9. REMOVE FOLLOWING PARTS FROM WHEEL CYLINDER

(a) Two boots
(b) Two pistons
(c) Two piston cups
(d) Spring
INSPECTION AND REPAIR OF REAR BRAKE

COMPONENTS
1. INSPECT DISASSEMBLED PARTS
Inspect the disassembled parts for wear, rust or damage.
2. INSPECT 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. INSPECT BRAKE SHOE LINING THICKNESS

If the shoe lining is less than minimum or shows signs of
uneven wear, replace the brake shoes.
HINT: If any of the brake shoes have to be replaced, re–
place 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 im–
proper, repair the lining with a brake shoe grinder, or re–
place the brake shoe assembly.
BR–43
INSTALLATION OF REAR BRAKE

(See page BR–40)
HINT: Assemble the parts in the correct direction as
shown.

FOLLOWING PARTS:
(a) Two piston cups
(b) Two pistons
(c) Two boots
2. ASSEMBLE WHEEL CYLINDER

(a) Install the spring and two piston cups into the wheel
cylinder. Check that the flanges of the piston cups
are pointed inward.
(b) Install the two pistons.
(c) Install the two boots.
3. INSTALL WHEEL CYLINDER
Install the wheel cylinder on the backing plate with the
two bolts.
BR–44
4. CONNECT BRAKE TUBE TO WHEEL CYLINDER

Using SST, connect the brake tube.
SST 09751–36011
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

bing face.
(a) Using pliers, connect the parking brake cable to the
lever.
BR–45
(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

bing 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 ad–
juster 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 adjust–
ing bolt turns.
If the adjuster does not turn, check for incorrect instal–
lation of the rear brakes.
BR–46
(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 diame–
ter of the brake shoes. Check that the difference be–
tween 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

BLEED BRAKE SYSTEM
(See page BR–8)

BR–47
BRAKE SYSTEM – Rear Brake – 2WD (Duo–Servo Type)
REAR BRAKE
2WD (Duo–Servo Type)
COMPONENTS
REMOVAL OF REAR DRUM BRAKE

(Single tire)
Remove the brake drum.
(Double tire)
Remove the rear axle shaft and remove the drum with the
axle hub.
BR–48
HINT: If the brake drum cannot be removed easily,

perform the following steps.
adjustment by turning the adjusting bolt.
3. REMOVE TWO SHOE RETURN SPRINGS
Using SST, remove the two return springs.

SST 09717–20010
4. REMOVE ADJUSTING CABLE, SHOE GUIDE PLATE,

CABLE GUIDE AND ADJUSTING LEVER
(a) Push up the lever and remove the cable, shoe guide
plate and cable guide.
(b) Take off the spring from the lever and remove the le–
ver and spring.
5. REMOVE TWO TENSION SPRINGS

Using pliers, remove the two tension springs.
6. REMOVE SHOES, ADJUSTER AND STRUT

(a) Using SST, remove the shoe hold down springs,
cups and pins.
SST 09718–00010
(b) Remove the shoes, adjuster and strut.
BR–49
(c) Disconnect the parking brake cable from the parking

brake lever
7. REMOVE PARKING BRAKE LEVER

Using a screwdriver, remove the parking brake lever.
8. DISCONNECT BRAKE TUBE FROM WHEEL CYLINDER

Using SST, disconnect the brake tube. Use a container to
catch the brake fluid.
SST 09751–36011
Remove the two bolts and wheel cylinder.
10. REMOVE FOLLOWING PARTS FROM WHEEL CYL-

INDER
(a) Two piston rods
(b) Two boots
(c) Two pistons
(d) Two piston cups
(e) Spring
BR–50

COMPONENTS

2. INSPECT BRAKE DRUM INSIDE DIAMETER

3. INSPECT BRAKE SHOE LINING THICKNESS

place 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 im–
proper, repair the lining with a brake shoe grinder, or re–
BR–51
INSTALLATION OF REAR BRAKE

(See page BR–47)
shown.

FOLLOWING PARTS
(a) Two piston cups
(b) Two pistons

(a) Install the spring and two piston cups into the wheel
cylinder. Check that the flanges of the piston cups
are pointed inward.
(b) Install the two pistons.
(c) Install the boots and rods.

Install the wheel cylinder on the backing plate with the
two bolts.
4. CONNECT BRAKE TUBE TO WHEEL CYLINDER

Using SST, connect tube.
SST 09751–36011
BR–52
5. APPLY HIGH TEMPERATURE GREASE TO FOLLOW–

ING PARTS:
(a) Backing plate and brake shoe contact points
(b) Piston rod and brake shoe contact points
(c) Adjusting bolt

(d) Adjuster and brake shoe contact point
6. INSTALL PARKING BRAKE LEVER

Using pliers, install the parking brake lever with a new
C–washer.
7. INSTALL REAR SHOE

(a) Install the parking brake cable to the parking
brake lever.
(b) Set the rear brake shoe in place with the end of
the shoe inserted in the piston rod. Using SST, in–
stall the shoe hold–down spring and pin.
SST 09718–00010
8. INSTALL STRUT AND FRONT SHOE

(a) Install the strut with the spring.
(b) Set the front brake shoe in place with the end of
the shoe inserted in the piston rod and the strut in
place. Using SST, install the shoe hold–down
spring and pin.
SST 09718–00010
BR–53
9. INSTALL TWO TENSION SPRINGS

Using pliers, install the two tension springs.
10. INSTALL ADJUSTER

Using a screwdriver, open the shoes and install the ad–
juster.
11. INSTALL SHOE GUIDE PLATE, CABLE GUIDE,

ADJUSTING CABLE AND RETURN SPRINGS
(a) Install the shoe guide plate, cable guide and adjust–
ing cable.
(b) Using SST, install the front return spring and then
install the rear return spring.
SST 09718–20010
12. INSTALL ADJUSTING LEVER

(a) Install the tension spring to the rear shoe.
(b) Hook the adjusting lever with the cable and install
the lever.
(c) Hook the adjusting lever with the tension spring.
BR–54
13. CHECK OPERATION OF AUTOMATIC ADJUSTER

MECHANISM
(a) Pull the adjusting cable backward as shown, and re–
lease. Check that the adjusting bolt turns.
If the bolt does not turn, check for incorrect installation
of the rear brakes.
(b) Adjust the adjuster to the shortest possible length.

(c) Install the drum.
(d) Turn the brake drum in reverse direction and depress
the brake pedal. Repeat this procedure until a click–
ing sound can no longer be heard.

DRUM
(a) Remove the drum.
(b) Measure the brake drum inside diameter and diame–
ter of the brake shoes. Check that the difference be–
tween the diameters is the correct shoe clearance.
15. INSTALL BRAKE DRUM

(Single tire)
Install the brake drum.
(Double tire)
Install the brake drum with axle hub and install the rear
axle shaft. (See page SA–128)

BLEED BRAKE SYSTEM
(See page BR–8)

BR–55
BRAKE SYSTEM – Rear Brake – 4WD
REAR BRAKE
4WD
COMPONENTS
REMOVAL OF REAR DRUM BRAKE

2. REMOVE REAR WHEEL

HINT: If the brake drum cannot be removed easily, per–
form the following.
adjustment by turning the adjusting bolt clockwise.
BR–56
4. REMOVE REAR 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 rear shoe
and remove the rear shoe.
(d) Remove the anchor spring from the. front shoe.
5. REMOVE FRONT SHOE

(a) Using SST, remove the shoe hold–down spring,
cups and pin.
SST 09718–00010
(b) Remove the return spring from the front shoe.
(c) Disconnect the parking brake cable No. 1 from the

parking brake bellcrank No.3.
(d) Remove the front shoe with adjuster.
(e) Disconnect the parking brake cable from the front
shoe.
6. REMOVE ADJUSTER FROM FRONT SHOE

(a) Remove the adjusting lever spring.
(b) Remove the adjuster.
BR–57
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.
8. REMOVE AND DISASSEMBLE PARKING BRAKE

BELLCRANK
(a) Remove the clip and disconnect the parking brake
cable.
(b) Remove the tension spring.
(c) Using a screwdriver, remove the bellcrank No.3

from the backing plate with parking brake cable
No. 2.
(d) Remove the parking brake bellcrank No. 1 or No. 2
and dust cover with the two bolts.
(e) Remove the bellcrank boot from the bellcrank
bracket.
(f) Remove the C–washer and pin.

(g) Remove the par–king brake bellcrank from the bell–
crank bracket.

SST 09751–36011
(b) Remove the two bolts and the wheel cylinder.
BR–58
10. DISASSEMBLE WHEEL CYLINDER

Remove the following parts from the wheel cylinder:
• Two boots
• Two pistons
• Two piston cups
• Spring

COMPONENTS
2. MEASURE BRAKE SHOE LINING THICKNESS

place all of the rear shoes in order to maintain even brak-
ing.
3. MEASURE BRAKE DRUM INSIDE DIAMETER

4. INSPECT REAR BRAKE LINING AND DRUM FOR PROP-

ER CONTACT
If the contact between the brake lining and drum is im
proper, repair the lining with a brake shoe grinder, or re
BR–59
ASSEMBLY OF REAR BRAKES

(See page BR–55)
shown.
1. ASSEMBLE AND INSTALL PARKING BRAKE BELL-

CRANK
(a) Apply high temperature grease to the rotating parts
of the bellcrank.
(b) Apply lithium soap base glycol grease to the bell–
crank boot and insert it to the parking brake bell–
crank.
(c) Install the parking brake bellcrank to the bellcrank
bracket.
(d) Install the pin with a new C–washer.
(e) Install the bellcrank boot to the parking brake bell–
crank bracket.
(f) Install the parking brake bellcrank and dust cover on
the backing plate.
BR–60
(g) Install the parking brake cable No.2 to the parking
brake bellcrank No. 1 or No. 2.
(h) Hook the bellcrank No. 3 to the cable No. 2, and
then install the bellcrank No.3 with a new C–
washer.

FOLLOWING PARTS:
(a) Two piston cups
(b) Two pistons

(a) Install the cup to the each piston.
(b) Install the spring and two pistons into the wheel
cylinder. Make sure flanges of the cups are
pointed inward.
(c) Install the two boots.

(a) Install the wheel cylinder on the backing plate
with two bolts.
(b) Using SST, connect the brake tube.
SST 09751–36011
5. APPLY HIGH TEMPERATURE GREASE TO BACKING

PLATE AND ADJUSTER
(a) Apply high temperature grease to the brake shoe
contact surfaces as shown.
BR–61
(b) Apply high temperature grease to the adjuster bolt

threads and ends.
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 TO FRONT SHOE

(a) Install the adjuster to the adjust lever.
(b) Install the adjust lever spring.
8. INSTALL FRONT SHOE

(a) Install the parking brake cable No. 1 to the parking
brake shoe lever.
(b) Hook the another side of the cable No. 1 to the
bellcrank No.3.
(c) Install the return spring to the front shoe.
(d) Set the front shoe in place with the end of the
shoe inserted in the piston.
(e) Using SST, install the shoe hold–down spring,
cups and pin.
SST 09718–00010
bing face.
BR–62
9. INSTALL REAR SHOE

(a) Install the anchor spring between the front and
rear shoes.
(b) Set the rear 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
bing face.
(d) Using SST, connect the return spring.

SST 09718–00010
10. ADJUST BELLCRANK

(a) Lightly pull the bellcrank in direction A until there
is no slack at part B.
(b) In this condition, turn the adjusting bolt so that di–
mension C will be 0.4 – 0.8 mm (0.016 – 0.031
in.).
(c) Lock the adjust bolt with the lock nut.
(d) Connect the parking brake cable to the parking

brake bellcrank and install the clip.
(e) Install the tension spring.
BR–63
11. CHECK OPERATION OF AUTOMATIC ADJUSTING

MECHANISM
(a) Move the parking brake lever of the front shoe
back and forth, as shown. Check that the adjuster
turns.
If the adjuster does not turn, check for incorrect instal–
lation of the rear brakes.
(b) Adjust the adjuster length to the shortest possible
amount.
(c) Install the brake drum.
(d) Pull the parking brake lever all the way up until a
clicking sound can no longer be heard.

DRUM
(a) Remove the brake drum.
(b) Measure the brake drum inside diameter and di–
ameter of the brake shoes. Check that the differ–
ence between the diameters is the correct shoe
clearance.
13. INSTALL BRAKE DRUM
14. INSTALL REAR WHEEL

BLEED BRAKE SYSTEM
(See page BR–8)

BR–64
BRAKE SYSTEM – Load Sensing Proportioning and By–Pass Valve (LSP & BV)
LOAD SENSING PROPORTIONING

AND BY–PASS VALVE (LSP & BV)
COMPONENTS
CHECK AND ADJUSTMENT OF FLUID PRESSURE

1. SET REAR AXLE LOAD
Rear axle load (includes vehicle weight):
2WD 1 ton, C & C (SRW) 900 kg (1,984 Ib)
1/2 ton 700 kg (1,543 Ib)
C & C (DRW) 1,150 kg (2,535 Ib)
4WD 800 kg (1,764 Ib)
HINT: (For C & C)
If the vehicle unladen weight exceeds the specification
above, set the rear axle load to the specification shown
below. (See step 4 on page BR–65)
Rear axle load (includes vehicle weight):
SRW 1,678 kg (3,699 Ib)
DRW 1,996 kg (4,400 Ib)
2. INSTALL LSPV GAUGE (SST) AND BLEED AIR
SST 09709–29017
BR–65
BRAKE SYSTEM – Load Sensing Proportioning and By–Pass Valve (LSP & 13V)
3. RAISE FRONT BRAKE PRESSURE TO 7,845 kPa (80
kgf/cm2, 1,138 psi) AND CHECK REAR BRAKE PRES–
SURE
Rear brake pressure:
2WD 1 ton, C & C (SRW) 4,413±490 kPa
(45±5kgf/cm 2, 640±71 psi)
1/2 ton 4,315 t 490 kPa
(44±5 kgf/cm 2, 626 ± 71 psi)
C & C (DRS) 4,707 ± 490 kPa
(48±5 kgf/cm 2, 683 ± 71 psi )
4WD Regular cab 3,923±490 kPa
(40±5 kgf/cm 2, 569±71 psi )
Extra cab 4,315±490 kPa
(43±5 kgf/cm 2, 626±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 brake pressure two seconds after
adjusting the specified fluid pressure.
If the brake pressure is incorrect, adjust the fluid pres–
sure.
4. (C&C)
RAISE FRONT BRAKE PRESSURE TO 11,768 kPa (120
kgf/cm2, 1,707 psi) AND CHECK REAR BRAKE PRES–
SURE
Rear brake pressure:
SRW 9,709 ± 588 kPa
(99 ± 6 kgf/cm2, 1,408 ± 85 psi)
DRW 8,336 ± 588 kPa
(85 ± 6 kgf/cm2, 1,209 ± 85 psi)
5. 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.)
Adjusting range:
2WD 72 – 84 mm (2.83 – 3.31 in.)
4WD 114 – 126 mm (4.49 – 4.96 in.)
HINT: One turn of the nut changes the fluid pressure as
shown in the table below.
Rear brake pressure
1/2 ton, C & C (SRW )
2WD
1 ton, C & C (DRW)
4WD
BR–66
(b) In event the pressure cannot be adjusted by the

No. 1 shackle, raise or lower the valve body.
Low pressure – Lower
High pressure – Raise
(c) Torque the nuts.
(d) Adjust the length of the No. 1 shackle again.
If it cannot be adjusted, inspect the valve housing.
6. 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.

2WD (SRW)
4WD (DRW)
4WD (Regular cab)
4WD (Extra cab)
If the measured value is not within standard, replace

the valve body.
BR–67
REMOVAL OF LSP & BV OR LSPV

(See page BR–64)
1. DISCONNECT SHACKLE NO.2 FROM BRACKET
2. REMOVE LSP & BV (LSPV) ASSEMBLY

(a) Using SST, disconnect the brake tube from the
valve body.
SST 09751–36011
(b) Remove the valve bracket mounting bolts and re–
move the LSP & BV (LSPV ) assembly.
DISASSEMBLY OF LSP & BV OR LSPV ASSEMBLY

1. REMOVE VALVE BRACKET
(a) Remove the nut and bolt as shown.
(b) Remove the two 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 SHACKLE NO. 1 AND NO.2

Remove the nut and bolt, and then remove the shackle
No.1 and No.2, and two plate washers from the load
sensing spring assembly.
BR–68
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
INSPECTION OF LSP & BV OR LSPV

INSPECT VALVE PISTON PIN AND LOAD SENSING
CONTACT SURFACE FOR WEAR
Wear limit: 0.7 mm (0.028 in.)
ASSEMBLY OF LSP & BV OR LSPV

(See page BR–64)
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 glycol grease to all rubbing ar–
eas.
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.
BR–69
3. CONNECT VALVE BODY AND NO. 1 SHACKLE TO LOAD

SENSING SPRING
CAUTION: When connecting the shackle to the load
sensing spring with a bolt and nut, insert the bolt from
the front side of vehicle.
INSTALLATION OF LSPV & BV OR LSPV

1. INSTALL LSP & BV (LSPV) ASSEMBLY TO FRAME

Using SST, connect the brake tubes.
SST 09751–36011
3. CONNECT SHACKLE NO.2 BRACKET

(a) Install the 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–64)
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 load sensing spring.
(c) Tighten the valve body mounting nuts.
6. BLEED BRAKE LINE (See page BR–8)
7. CHECK AND ADJUST LSP & BV OR (LSPV) FLUID

PRESSURE
(See page BR–64)
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–70
BRAKE SYSTEM – Rear–Wheel Anti–Lock Brake System
REAR–WHEEL ANTI–LOCK BRAKE SYSTEM

General Description
• The Rear–Wheel Anti–Lock Brake System is a brake system which controls the wheel cylinder hydraulic
pressure of the rear wheels during sudden braking and braking on slippery road surfaces, preventing the
rear wheels from locking.
• In case a malfunction occurs, a diagnosis function and fail–safe system have been adopted for the Rear–
Wheel Anti–Lock Brake System to increase serviceability.
LOCATION OF SYSTEM COMPONENTS
FUNCTION OF COMPONENTS
No. Components Function
Speed Sensor Detects the wheel speed from the rotation of the rear differential ring gear.
Solenoid Relay Supplies electric current to the solenoid valve of the actuator.
Controls the brake fluid pressure to rear brake wheel cylinders through signals from
Actuator the ECU.
Deceleration Sensor Detects the vehicle deceleration rate from the deceleration of the body.
REAR ANTI–LOCK Lights up to alert the driver when trouble has occurred in the Rear–wheel Anti–Lock
Warning Light Brake System.
According the wheel speed signals from the speed sensor and vehicle deceleration
ECU signals from the deceleration sensor, it calculates acceleration, deceleration and slip
values and sends signals to the actuator to control brake fluid pressure.
BR–71
WIRING DIAGRAM
BR–72
CONNECTORS
BR–73
Diagnosis System
DESCRIPTION
If a functional malfunction occurs, diagnosis system will
identify the problem and ECU stores the codes for the
trouble items.
At the same time, the system informs the driver of a mal–
function via the ”REAR ANTILOCK” warning light in the
combination meter.
By turning on the ignition switch and disconnecting the
service connector, the trouble can be identified by the
number of blinks (diagnosis code) of the warning light.
In event of two codes, that having the smallest number
(code) will be identified first.
HINT: The warning light do not show the diagnostic
trouble codes while the vehicle is running.
INSPECTION OF DIAGNOSIS SYSTEM

1. INSPECT BATTERY POSITIVE VOLTAGE
Inspect that the battery positive voltage is about 12 V.
2. CHECK THAT WARNING LIGHT TURNS ON

(a) Turn the ignition switch to ON.
(b) Check that the ”REAR ANTILOCK” warning light
turns on for about 3 seconds.
If not, inspect and repair or replace the fuse, bulb and
wire harness.
3. READ DIAGNOSTIC TROUBLE CODE

(b) Disconnect the service connector.
SST 09843–18020
(c) Using SST, connect the terminal Tc to E, of the data

link connector 1.
BR–74
(d) In event of a malfunction, 4 seconds later the warn–

ing light will begin to blink. Read the number of
blinks.
(See DIAGNOSTIC TROUBLE CODE on page
BR–75)
HINT: The first number of blinks will equal the first digit
of a two digit diagnostic trouble code. After a 1.5 sec–
onds pause, the 2nd number of blinks will equal the
2nd number of a two digit code. If there are two or more
codes, there will be a 2.5 seconds pause between
each, and indication will begin after 4.0 seconds pause
from the smaller value and continue in order to larger.
(e) If the system is operating normally (no malfunction),
the warning light will blink 2 times per second.
(f) Repair the malfunctioning parts.

(g) After the malfunctioning parts has been repaired,
clear the diagnostic trouble codes stored in the ECU .
(See page BR–76)
HINT: If you disconnect the battery cable while re-
pairing, all diagnostic trouble codes in the ECU will
be erased.
(h) Disconnect the terminal Tc from El of the data link
connector 1.
(i) Connect the service connector.

Turn the ignition switch to ON, and check that the
”REAR ANTILOCK” warning light goes off after the
warning light goes on for about 2 seconds.
Code No. Light Pattern Diagnosi Trouble Part
s
Open circuit in solenoid relay circuit or solenoid

circuit
• Solenoid
• Solenoid relay
12 Short circuit in solenoid relay circuit
• Wire harness and connec–
tor of solenoid and/or sole–
noid relay circuit
25 Short circuit in solenoid circuit
DIAGNOSTIC TROUBLE CODE

BRAKE SYSTEM
• Speed sensor
Open or short circuit in speed sensor circuit • Wire harness and connec–
33 tor of speed sensor circuit
–
41 Low battery positive voltage (9.5 V or lower
Rear–Wheel Anti–Lock Brake System

• Battery
Abnormally high battery positive voltage

42 0 7 V or higher)
43 Mechanical malfunction in deceleration sensor

• Deceleration sensor
• Wire harness and connec–
tor of deceleration sensor
44 Electrical malfunction in deceleration circuit
sensor circuit
Always ON Malfunction in ECU • ECU
BR–75
BR–76
CLEARING OF DIAGNOSTIC TROUBLE

CODES
CLEAR DIAGNOSTIC TROUBLE CODES
(b) Disconnect the service connector.
HINT: Keep the vehicle stopped (vehicle speed 0 km/h
(0 mph)).
(c) Using SST, connect the terminal Tc to E, of the data

link connector 1.
SST 09843–18020
(d) Clear the diagnostic trouble codes stored in ECU by

depressing the brake pedal 8 or more times within 3
seconds.
(e) Check that the warning light shows the –normal

code.
If the warning light still shows the diagnostic trouble
codes, check for cause and repair or replace the
trouble
parts, then clear the diagnostic trouble codes again.
(f) Connect the service connector.

(g) Disconnect the terminal Tc from E, of the data link
connector 1.
BR–77
(h) Check that the warning light goes off.

BR–78
Troubleshooting
Problem No.
Always comes on after ignition switch is turned to ON.
Does not come on for about 3 seconds after ignition switch on.
”REAR ANTILOCK” warning
light
Comes on and off.
Comes on while running.
Brakes pull.
Braking inefficient.
Rear–Wheel Anti–Lock Brake System operates at ordinary braking.
Rear–Wheel Anti–Lock Brake System operates just before stopping at

Brake working ordinary braking.
Brake pedal pulsates abnormally while Rear–Wheel Anti–Lock Brake

System is operating.
Skidding noise occurs while Rear–Wheel Anti–Lock Brake System

working. (Rear–Wheel Anti–Lock Brake System works inefficiently)
”REAR ANTILOCK” warning light comes on.
Disconnect service connector and con–

nect the terminal Tc to E, of the data
link connector 1. (See page BR–73)
Does warning light always come on or See diagnostic trouble code.

show the normal code ? (See page BR–75)
(Ignition switch on)
YES
Continued on page BR–79

BR–79
Continued from page BR–78
Is connector of ECU properly connected ? Faulty connector.

And are all terminals in the connector ?
YES
Is there 10 – 14 V between terminal IG Faulty power circuit.

on ECU wire harness side connector and
body ground ? (Ignition switch on)
YES
Does warning light come off when both Short circuit in wire harness between ECU termi–
NO
the ECU connector and solenoid relay nal W and solenoid relay terminal W.
(Come
connector are disconnected ? on)
YES
(Come off)
Faulty ECU.
BR–80
”REAR ANTILOCK” warning light does not come on for about 2 seconds after
ignition switch on.
Disconnect service connector and ground

the terminal W of the wire harness side
connector. (Ignition switch on)
Bulb burned out or open circuit in wire harness

Does warning light come on ? between warning light and service connector ter–
minal W.
YES
Disconnect connector from ECU and sole–
noid relay, and ground terminal W of ECU
wire harness side connector.
(ignition switch on)
Does warning light come on ? Open circuit in wire harness between ECU termi–
nal W and warning light.
YES
With ignition switch off, disconnect sole–

noid relay connector, and check continu–
ity between terminal W and BS on sole–
noid relay side.
Reverse tester leads and check again. Is Short circuit in solenoid relay inside diode.
there one way continuity between termi–
nals ?
YES HINT: If the diode is short–circuited, a malfunction
Faulty ECU. at ECU terminal W will occur.
When inspecting the terminal, connect the ECU con–
nector and disconnect solenoid relay connector. Then
turn the ignition switch on, and check that the warn–
ing light goes on. If it does, the ECU terminal is OK.
BR–81
”’REAR ANTILOCK” warning light comes on and off .
• Short circuit in wire harness between ECU terminal TS and data link connector 1 terminal Ts.
• Short circuit in wire harness between ECU terminal TC and data link connector 1 terminal Tc.
• Braking inefficient.
• Rear–Wheel Anti–Lock Brake System operates at ordinary braking.
• Rear–Wheel Anti–Lock Brake System operates just before stopping at
ordinary braking.
• Brake pedal pulsates abnormally while Rear–Wheel Anti–Lock Brake System
working.

nect the terminal Tc to E, of the data
link connector 1. (See page BR–73)
Does warning light show the diagnostic See diagnostic trouble code.
normal code ? (Ignition switch on) (See page BR–75)
YES
Try deceleration sensor operation diagno– Faulty deceleration sensor or sensor installation
sis system. Is sensor OK ?(See page faulty.
BR–84)
YES
Try speed sensor diagnosis system. Inspect speed sensor, and replace if necessary.
Is speed sensor OK ? (See page BR–84)
YES
Is speed sensor installed in place ? And is Speed sensor– installation faulty.

installation bolt tightened securely ?
YES
Continued on page BR–82
BR–82
Continued from page BR–81
Is there foreign material or ferric chips YES Clean chips from speed sensor.
on the speed sensor tip ?
Disconnect connector from ECU and

inspect continuity between speed
sensor terminals on wire harness side.
Does any abnormal change occur in YES

Faulty wire harness.
continuity when the connector or wire (Ab–
harness of speed sensor and intermedi– normal
ate connectors are twisted or bent ? change)
NO
(No change)
Inspect actuator operation.
(See page BR–88)
Is actuator operation OK ? Faulty actuator.

YES
Inspect differential ring gear serrations. Faulty sensor rotor.

Are serrations OK ? (Differential ring gear)
YES
Faulty ECU.
BR–83
Rear–Wheel Anti–Lock Brake System works inefficiently.

nect the terminal Tc to E , of the data
link connector
1. (See page BR–73)
Does warning light show the diagnostic See diagnostic trouble code.
normal code ? (See page BR–75)
YES
Is there battery positive voltage be– Open circuit in stop light switch and/or wire
tween ECU terminal STP and body harness.
ground when depressing brake pedal ?
YES
Inspect actuator.
(See page BR–87)
BR–84
Deceleration Sensor and Speed

Sensor Diagnosis System
PRECAUTION
• While checking the deceleration sensor and speed sen–
sor diagnosis system, the Rear–Wheel Anti–Lock Brake
System does not work and brake system works as nor–
mal brake system.
INSPECTION OF DIAGNOSIS SYSTEM
1. INSPECT BATTERY POSITIVE VOLTAGE
Inspect that the battery positive voltage is about 12 V.
2. CHECK THAT WARNING LIGHT TURNS ON
(b) Check that the ”REAR ANTI–LOCK” warning light
turns on for about 3 seconds.
If not, inspect and repair or replace the fuse, bulb and
wire harness.
(e) Check that the ”REAR ANTI–LOCK” warning light
turns off.
(d) Turn the ignition switch to OFF.
3. PERFORM FOLLOWING STEPS

(a) Using SST, connect the terminal Ts to El of the data
link connector 1.
SST 09843–18020
(b) Start the engine.
(c) (2 WD model)
Check that the warning light blinks about 4 times
every 1 second after blinking 1 time in 1.5 seconds
as shown.
(d) (4 WD model)
Check that the warning light blinks about 4 times
every 1 second after blinking 2 times in 2.0 seconds
as shown.
BR–85
(e) Drive the vehicle straight ahead at about 20 km/h

(12.4 mph) or more, depress the brake pedal
strongly.
(f) Check that the warning light turns on while braking.
(g) Drive the vehicle straight ahead at about 50 km/h

(31 mph) or more, and stop the vehicle.
(h) Check that the warning light blinks about 4 times
every 1 second as shown.
(i) Using SST, connect terminals Tc and E 1 of the data

link connector 1.
SST 09843–18020
(j) Check that the warning light shows the normal

code.
(k) In event of a malfunction, 2.5 seconds later the

warning light will begin to blink. Read the number of
blinks.
(See DIAGNOSTIC TROUBLE CODE on page BR–86)
HINT: The first number of blinks will equal the first digit
of a two digit diagnostic trouble code. After a 1.5 sec–
onds pause, the 2nd number of blinks will equal the 2nd
number of a two digit code. If there are two or more
codes, there will be a 2.5 seconds pause between
each,
and indication will begin after 2.5 seconds pause from
the smaller value and continue in order to larger.
BR–86
(I) If the system is operating normally (no malfunction),

the warning light will blink once every 0.5 seconds.
(m) Repair the system.
(n) After the malfunctioning components have been re–
paired, clear the diagnostic trouble codes stored in
the ECU.
(See page BR–76)
HINT: If you disconnect the battery cable while re-
pair–
ing, all diagnostic trouble codes in the ECU will be
erased.
(o) Remove the SST from terminals Ts, Tc and E 1 of the
data link connector 1.
SST 09843–18020
DIAGNOSTIC TROUBLE CODE

Code MAlfunctioning
Light Pattern Diagnosis Part
No.
Speed sensor and sensor rotor

are normal
Speed sensor
Low output voltage of speed Sensor rotor
sensor signal Differential
ring gear
Sensor rotor
Abnormal change of output Differential
voltage of speed sensor signal ring gear
Sticking of deceleration Deceleration

sensor pendulum sensor
BR–87
Brake Actuator
COMPONENTS
INSPECTION OF BRAKE ACTUATOR

1. CHECK BRAKE FLUID PRESSURE
(a) Remove the bleeder plug from the rear wheel cylin–
der and connect SST.
SST 09709–29017
(b) Bleed the air from SST.
(c) With the engine off, hold the brake pedal depressed
for about 10 seconds with the pressure at 1,961
kPa (20 kgf/crn2, 284 psi ), and check that there is
no change in the pedal reserve distance.
If there is a change in the brake pedal reserve distance,
check the brake line, master cylinder and wheel cylin-
der for fluid leakage.
BR–88
(d) With the engine running, hold the brake pedal de–
pressed for about 1 0 seconds with the pressure at
5,844 kPa (60 kgf/cm2, 853 psi), and check that
there is no change in the pedal reserve distance.
If there is a change in the brake pedal reserve distance,
inspect the brake actuator.
2. CHECK POWER STEERING FLUID PRESSURE

(a) (4WD w/ 22R–E Engine)
Using SST, disconnect the power steering pressure
line from the power steering pump.
SST 0963 1–22020
(b) (Except 4WD w/ 22R–E Engine)
Remove the union bolt and disconnect the power
steering pressure line from the power steering
pump.
(c) Connect the power steering pressure gauge be–

tween the power steering pump and hose with the
gauge valve on the actuator side.
(d) Bleed the system and check that the fluid level is
correct.
(See page BR–94)
(e) Start the engine and run it at idle.

(f) Close the pressure gauge valve and observe the
reading on the gauge.
Minimum pressure: 7,355 kPa (75 kgf/cm2, 1,067 psi)
HINT:
• Do not keep the valve closed for more than 10 sec.
onds.
• Check with the fluid temperature at least 80C
(176F).
If pressure is low, repair or replace the power steering
pump.
3. CHECK RELATION BETWEEN BRAKE FLUID AND
POWER STEERING FLUID PRESSURE
HINT:
• Be sure the tires in the straight–ahead position.
• Be sure the power steering pressure gauge valve is;
fully open.
• Check with the power steering fluid temperature a–
least 80C (176F).
BR–89
With the engine running, the brake and power steering

fluid pressure should conform to the following table.
Brake Fluid
Pressure
PS Fluid
Pressure
If not within specification, check the actuator.
4. CHECK ACTUATOR OPERATION

(a) Disconnect the connector from the actuator.
(b) Disconnect the connector from the solenoid relay.
(c) Connect the actuator checker (SST) to the actuator,
solenoid relay and body side wire harness through
the sub–wire harness (SST) as shown.
SST 09990–00150 and 09990–00205
(d) Connect the red cable of the checker to the battery
positive (+) terminal and black to the negative ( – )
terminal.
(e) Start the engine, and run it at idle.
(f) Turn the selector switch of actuator checker to
”REAR” position.
(g) Strongly depress the brake pedal and hold it.
(h) Push the ON/OFF switch, and check that the brake
pedal sinks a little and that it returns to the original
position when the switch is released.
NOTICE:
• To avoid damaging the master cylinder piston cup, do
not push on SST switch before depressing the brake
pedal and do not release your foot from the brake
pedal while SST switch is pushing on.
• Do not keep the ON/OFF switch pushing more than 10
seconds.
If operation is not as specified, replace the actuator.
(i) Release the switch, then release the brake pedal.
BR–90
5. REMOVE ACTUATOR CHECKER (SST)

Remove SST, then connect the connectors of the actua–
tor and solenoid relay.
SST 09990–00150 and 09990–00205
6. REMOVE SST FROM WHEEL CYLINDER

SST 09709–29017
7. REMOVE PRESSURE GAUGE FROM PS PUMP
Remove the pressure gauge from the PS line, then bleed
the power steering system.
8. BLEED SYSTEM
(a) Fill brake reservoir with brake fluid.
(b) Fill PS reservoir with fluid.
Fluid type: ATF DEXRON ll
(c) Bleed the system.
(See page BR–94)
REMOVAL OF BRAKE ACTUATOR

1. REMOVE BATTERY
Disconnect the wire harnesses from the terminals and re–
move the battery and tray.
2. DISCONNECT CONNECTOR
Disconnect the connector from the actuator.
3. DISCONNECT TWO BRAKE TUBES

Using SST, disconnect the two brake tubes.
SST 09751–36011
BR–91
4. DISCONNECT POWER STEERING LINES FROM ACTUA–

TOR
HINT: Turn the steering wheel clockwise until it locks
before disconnecting the PS lines. And if you cannot
work from the upper side, work from the wheel house.
(a) Remove the two union bolts and disconnect the two
power steering pressure tubes.
(b) (22R–E Engine)
Disconnect the power steering line hose.
(c) (3VZ–E Engine)
Disconnect the two power steering line hoses.
5. REMOVE PS TUBE CLAMP INSTALLATION BOLT

Remove the installation bolt of the power steering tube
clamp.
6. REMOVE ACTUATOR
Remove the three bolts and remove the actuator from the
wheel house.
7. REMOVE BRACKET FROM ACTUATOR

Remove the three bolts and separate the actuator and
bracket.
BR–92
INSTALLATION OF BRAKE ACTUATOR

1. INSTALL BRACKET TO ACTUATOR
Install the bracket to the actuator with the three bolts.
2. INSTALL ACTUATOR
Install the actuator in place and tighten the three bolts.
HINT: Install the bolts in following order.
(1) Front side bolt
(2) Wheel house side bolt of rear bolts
(3) Upper side bolt on frame of rear bolts
3. CONNECT POWER STEERING LINES

(a) Set the pressure union and new gaskets in place,
then install the union bolt.
(b) Similarly connect the other pressure tube.
(c) Connect the PS line hose to the actuator, then fix it
with the hose clamp.
(d) (3VZ–E Engine)
Similarly connect the other PS line hose.
4. INSTALL PS TUBE CLAMP

Install the PS pressure tube clamp in place and tighten
the bolt.
5. CONNECT TWO BRAKE TUBES

Using SST, connect the two brake tubes to the actuator.
SST 09751–36011
HINT: First connect the painted brake tube to the
painted hole of the actuator, then the other.
BR–93
6. CONNECT CONNECTOR
Connect the connector to the actuator.
7. INSTALL BATTERY
Install the tray and battery in place, then connect the
wire harnesses to the terminals.
8. BLEED SYSTEM
(a) Fill brake reservoir with brake fluid.
(b) Fill PS reservoir with fluid.
Fluid type: ATF DEXRONII
(c) Bleed the system.
(See page BR–94)
BR–94
BLEEDING OF REAR–WHEEL ANTI–LOCK

BRAKE SYSTEM
HINT: Whenever PS hoses or PS pressure tube are dis–
connected or actuator is removed from the vehicle, the
Rear–Wheel Anti–Lock Brake System should be bled in the
following procedure.
At the other times, use the conventional procedure.
1. BLEED POWER STEERING SYSTEM

Use the conventional procedure.
2. BLEED BRAKE SYSTEM
(a) Bleed the system with the engine running.
(b) Bleed the system with the engine off.
3. BLEED POWER STEERING SYSTEM AGAIN

(a) Disconnect the connector from the actuator.
(b) Disconnect the connector from the solenoid relay.
(c) Connect the actuator checker (SST) to the actuator,
solenoid relay and body side wire harness through
the sub–wire harness (SST) as shown.
SST 09990–00150 and 09990–00205
(d) Connect the red cable of the checker to the battery
positive (+) terminal and black to the negative¿ – )
terminal.
(e) Start the engine, and run it at idle.
(f) Turn the selector switch of actuator checker to
”AIR BLEED” position.
(g) Strongly depress the brake pedal and hold it.
(h) Push on and release the ON/OFF switch three sec–
onds each for five times.
NOTICE:
• To avoid damaging the master cylinder piston cup, do
not push on SST switch before depressing the brake
pedal and do not release your foot from the brake
pedal while SST switch is pushing on.
• Do not keep the ON/OFF switch pushing more than 10
seconds.
(i) Release the switch, then release the brake pedal.
(j) Check the PS and brake fluid level, and add the fluid
if necessary.
(k) Remove SST, then connect the connectors of the
actuator and solenoid relay.
SST 09990–00150 and 09990–00205
BR–95
Control Relay
INSPECTION OF SOLENOID RELAY
INSPECT SOLENOID RELAY OPERATION
Inspect the relay continuity between terminals.
Terminal
Condition
Constant
Apply battery positive
voltage between
terminals 1 and ’6
If relay operation is not as specified, replace the solenoid

relay.
BR–96
Speed Sensor
INSPECTION OF SPEED SENSOR

1. INSPECT SENSOR INSTALLATION
Check that the sensor installation bolt is tightened prop–
erly.
If not, tighten the bolt.
2. INSPECT SPEED SENSOR

(a) Disconnect the speed sensor connector.
(b) Measure the resistance between terminals.
Resistance: 580 – 700
If resistance value is not as specified, replace the sensor.
(c) Check that there is no continuity between each ter–

minal and sensor body.
If there is continuity, replace the sensor.
(d) Connect the speed sensor connector.
BR–97
3. VISUALLY INSPECT SENSOR ROTOR SERRATIONS

(a) Disconnect the speed sensor wire harness clamp
bolt.
(b) Remove the speed sensor installation bolt and pull
out the speed sensor.
(c) Remove the differential carrier assembly.

(See page SA–136)
NOTICE: To prevent damage to the ring gear serrations,
do not strike the ring gear.
(d) Inspect the ring gear (sensor rotor) serrations for

scratches, cracks, warping or missing teeth.
If necessary, replace the ring gear.
(e) Install the differential carrier assembly.

(See page SA–151 )
(f) Install the speed sensor and tighten the installation

bolt.
(g) Set the speed sensor wire harness clamp in place
and tighten the clamp bolt.
BR–98
INSPECTION OF SPEED SENSOR AND

SENSOR ROTOR SERRATIONS
(REFERENCE)
INSPECT SPEED SENSOR AND SENSOR ROTOR SERRA–
TIONS BY USING AN OSCILLOSCOPE
(a) Remove the glove box assembly and disconnect the
radio speaker connector.
(b) Disconnect the connector from the rear–wheel anti–
lock brake system ECU.
(c) Connect an oscilloscope to the terminals RR + and
RR – on the wire harness side connector.
(d) Run the vehicle at 20 km/h 0 2.4 mph), and inspect
speed sensor output wave.
(e) Check that C is 0.4 V or more.

If it is not as specified, replace the speed sensor.
M Check that B is 70% or more of A.
If it is not as specified, replace the sensor rotor.
(g) Remove the oscilloscope and connect the connector
to the ECU.
(h) Connect the radio speaker connector and install the

glove box assembly.
BR–99
Deceleration Sensor
INSPECTION OF DECELERATION SENSOR

INSPECT SENSOR INSTALLATION
(a) Remove the two clips, then remove the instrument
lower center cover.
(b) Inspect that the sensor direction is correct.

(c) Check that the sensor installation bolts are tight–
ened properly.
If not, tighten the bolts.
Torque: 5.4 N–m (55 kgf–cm, 48 in.–lbf)
(d) Install the instrument lower center cover and two

clips.
BR–100
Rear–Wheel Anti–Lock Brake System

Circuit
REMOVAL OF REAR–WHEEL ANTI–LOCK BRAKE
SYSTEM ECU
1. REMOVE GLOVE BOX ASSEMBLY
Remove the four screws and a bolt, then remove the
glove box assembly and disconnect the radio speaker
connector.
2. REMOVE ECU
(a) Remove the two screws and a nut.
(b) Pull out the ECU.
INSPECTION OF SYSTEM CIRCUIT

1. INSPECT SYSTEM CIRCUIT WITH CONNECTOR CON–
NECTED
Using a voltmeter with high impedance (10 kN mini–
mum), measure the voltage at each terminal and body
ground.
Tester Connection Condition Voltage Trouble Part

Ignition switch ON
Ignition switch ON and ”REAR ANTILOCK”
warning light goes on
Solenoid relay,
Ignition switch ON Actuator
Ignition switch ON and ”REAR ANTILOCK”

Ignition switch ON
Warning light
Ignition switch ON and ”REAR ANTILOCK” bulb
BR–101
2. INSPECT SYSTEM CIRCUIT WITH CONNECTOR DIS–

CONNECTED
(a) Disconnect the connector from the ECU and inspect
at the wire harness side connector.
Voltage or
Tester Connection Check Item Condition Resistance Value Trouble Part
Ignition SW on and PKB lever pulled PKB switch,

Voltage level warning
Ignition SW on and PKB lever returned switch
Resistance Speed sensor

Voltage Wire harness
Ignition SW on ECU–IG fuse,
Voltage wire harness
Ignition SW off
Resistance Solenoid relay
Voltage Ignition SW off and brake pedal depressed Stop light

switch, stop
Continuity Ignition SW off and brake pedal returned light
Continuity Wire harness
If the circuit is not as specified, check and repair or

replace the trouble part shown in the table above.
(b) Connect the connector.
INSTALLATION OF ECU
1. INSTALL ECU
Install the ECU in place with a nut and two screws.
2. INSTALL GLOVE BOX ASSEMBLY
Connect the radio speaker connector and install the glove
box assembly in place and install the four screws and a
bolt.

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BR–1

Brakes pull Tires improperly inflated Inflate tires to proper pressure

Brakes pull Tires improperly inflated Inflate tires to proper pressure

Brake booster faulty Repair booster

Snapping or clicking (Drum brake)

Other brake system components faulty Repair or replace as necessary

CHECKS AND ADJUSTMENTS

4. CHECK THAT PEDAL RESERVE DISTANCE IS CORRECT,

OPERATIONAL TEST OF BRAKE BOOSTER

BLEEDING OF BRAKE SYSTEM

1. FILL BRAKE RESERVOIR WITH BRAKE FLUID

2. BLEED MASTER CYLINDER

3. CONNECT VINYL TUBE TO WHEEL CYLINDER BLEEDER

6. BLEED LSP & BV

CHECK AND ADJUSTMENT OF PARKING BRAKE

1. DISCONNECT LEVEL WARNING SWITCH CONNECTOR

4. REMOVE MASTER CYLINDER

DISASSEMBLY OF MASTER CYLINDER

3. REMOVE TWO GROMMETS

4. PLACE CYLINDER IN VISE

5. REMOVE PISTON STOPPER BOLT

6. REMOVE TWO PISTONS AND SPRINGS

(c) Place a rag and two wooden blocks on the work

INSPECTION OF MASTER CYLINDER

1. INSPECT CYLINDER BORE FOR RUST OR SCORING

2. INSPECT CYLINDER FOR WEAR OR DAMAGE

2. INSTALL TWO SPRINGS AND PISTONS

4. INSTALL TWO GROMMETS

6. INSTALL MASTER CYLINDER BOOT

INSTALLATION OF MASTER CYLINDER

2. INSTALL MASTER CYLINDER

3. CONNECT TWO BRAKE TUBES

4. CONNECT LEVEL WARNING SWITCH CONNECTOR

1. REMOVE MASTER CYLINDER

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

INSTALLATION OF BRAKE BOOSTER

(c) Turn the SST upside down, and set it on the

2. INSTALL BRAKE BOOSTER, GASKET AND CLEVIS

3. CONNECT CLEVIS TO BRAKE PEDAL

5. INSTALL MASTER CYLINDER

6. CONNECT HOSE TO BRAKE BOOSTER

7. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND

8. CHECK FOR FLUID LEAKAGE

9. CHECK AND ADJUST BRAKE PEDAL

10. PERFORM OPERATIONAL CHECK

REPLACEMENT OF BRAKE PADS

1. REMOVE FRONT WHEEL

2. INSPECT PAD LINING THICKNESS

(b) Lift up the brake cylinder and suspend it so the hose

4. REMOVE FOLLOWING PARTS:

5. CHECK ROTOR DISC THICKNESS

7. INSTALL PAD SUPPORT PLATES

8. INSTALL NEW PADS

(c) Install the two pads so the wear indicator plate is

(c) (PD60 Type)

(e) Install and torque the installation bolts.

10. INSTALL FRONT WHEEL