System Brake

SERVICIO NACIONAL DE APRENDIZAJE
CENTRO DE TECNOLOGIAS DEL TRANSPORTE

MATERIAL DE APOYO INGLES GUIA SISTEMA DE FRENOS HIDRAULICOS
INSTRUCTOR TECNICO: HERNAN DAVID MENDOZA GALINDO
CHECK AND ADJUST BRAKE PEDAL HEIGHT
a. Check the pedal height.

Pedal height from dash panel:
Model
Specified Condition
LHD
(M/T)
152.9 to 162.9 mm (6.020

to 6.413 in.)
LHD
(A/T)
154.1 to 164.1 mm (6.067

to 6.461 in.)
RHD
(M/T)
156.9 to 166.9 mm (6.177

to 6.571 in.)
RHD
(A/T)
158.1 to 168.1 mm (6.224

to 6.618 in.)
b. Adjust the pedal height.

i.
ii.
Disconnect the connector from the stop light switch.

Remove the switch.
iii.
iv.
v.
Loosen the push rod clevis lock nut.

Adjust the pedal height by turning the push rod.
Tighten the lock nut.
Torque:
26 N*m{ 265 kgf*cm , 19 ft.*lbf }
vi.
Insert the switch into the adjuster until it slightly touches the pedal.
NOTICE:
Do not depress the pedal.
vii.
Turn the switch a quarter turn clockwise.

Torque:
1.5 N*m{ 15 kgf*cm , 13 in.*lbf } or less
NOTICE:
Do not depress the pedal.
viii.
ix.
Connect the connector to the switch.

Check the switch clearance.
Stop light switch clearance:
1.5 to 2.5 mm (0.059 to 0.098 in.)
2. CHECK BRAKE PEDAL FREE PLAY
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.
3. CHECK BRAKE PEDAL RESERVE DISTANCE
a. Release the parking brake lever. Start the engine.

b. Depress the pedal and check the pedal reserve distance.
i.
ii.
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.)
RHD (4WD and

pre-runner)
89.0 mm
(3.504 in.)
If the distance is not as specified, troubleshoot the brake system.
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).
2. DRAIN BRAKE FLUID

NOTICE:
Wash off brake fluid immediately if it comes in contact with any painted
surface.
3. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY
a. for Manual Transmission:

Disconnect the clutch reservoir tube from the master cylinder reservoir.
b. Disconnect the brake fluid level warning switch connector.
c. Using a union nut wrench, disconnect the 4 brake lines from the master
cylinder and brake tube way.
d. Remove the 2 nuts and brake tube way.

e. Pull out the master cylinder from the brake booster.
f.
Remove the O-ring from the master cylinder.
4. REMOVE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY

a. Remove the master cylinder pin.
b. Remove the reservoir and 2 grommets from the master cylinder.
CHECK AND ADJUST BRAKE BOOSTER PUSH ROD

NOTICE:
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.
b. Turn SST upside down, and then set it on the booster.

c. Measure the clearance between the booster push rod and pin head (SST).
Standard clearance:
0 mm (0 in
BRAKE BOOSTER (for TSAM Made LHD) > ON-VEHICLE

INSPECTION
1. CHECK BRAKE BOOSTER ASSEMBLY
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.
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.
2. CHECK BRAKE VACUUM CHECK VALVE ASSEMBLY
a. Check the check valve.

i.
ii.
iii.
Slide the clip and disconnect the vacuum hose.

Remove the check valve from the booster.
Check that there is ventilation from the booster to the engine, and no
ventilation from the engine to the booster.
HINT:
If the results are not as specified, replace the check valve.
VACUUM PUMP (DIESEL Engine) > INSPECTION

1. CHECK OPERATION OF CHECK VALVE SUB-ASSEMBLY
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.
2. CHECK VACUUM PUMP HOUSING
a. Check the inside surface of the housing for scoring.

If necessary, replace the vacuum pump assembly.
FRONT BRAKE > REMOVAL
HINT:
Use the same procedures for the LH side and RH side.

The procedures listed below are for the LH side.
1. REMOVE FRONT WHEEL

NOTICE:
surface.
3. REMOVE FRONT DISC BRAKE ANTI-RATTLE SPRING
a. Remove the 2 clips. Then remove the 2 pins.

b. Remove the spring.
4. REMOVE FRONT DISC BRAKE PAD

a. Remove the 2 disc brake pads.
5. REMOVE FRONT ANTI SQUEAL SHIM KIT

a. Remove the No. 1 and No. 2 shims from each pad.
6. REMOVE FRONT NO. 1 WHEEL CYLINDER TUBE LH
a. Using a union nut wrench, disconnect the tube from the cylinder.
7. REMOVE DISC BRAKE CYLINDER ASSEMBLY LH
FRONT BRAKE () > INSPECTION

1. CHECK BRAKE CYLINDER AND PISTON
a. Check the cylinder bore and pistons for rust or scoring.
If necessary, replace the cylinder and pistons.
2. CHECK PAD LINING THICKNESS
a. Using a ruler, measure the pad lining thickness.

Standard thickness:
11.5 mm (0.453 in.)
Minimum thickness:
1.0 mm (0.039 in.)
If the pad lining thickness is less than the minimum, replace the pad.
3. CHECK DISC THICKNESS

a. Using a micrometer, measure the disc thickness.
Standard thickness:
28.0 mm (1.102 in.)
Minimum thickness:
26.0 mm (1.024 in.)
If the disc thickness is less than the minimum, replace the disc
REAR BRAKE () > REMOVAL

HINT:
Use the same procedures for the LH side and RH side.

The procedures listed below are for the LH side.
1. CHECK BRAKE SHOE LINING THICKNESS
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.
2. REMOVE REAR WHEEL

NOTICE:
surface.
4. REMOVE REAR BRAKE DRUM SUB-ASSEMBLY

a. Release the parking brake lever, and remove the drum.
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.
REAR BRAKE () > INSPECTION

1. CHECK BRAKE DRUM INSIDE DIAMETER
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.
2. CHECK BRAKE SHOE LINING THICKNESS
a. Using a ruler, measure the thickness of the shoe lining.

Standard thickness:
5.1 mm (0.201 in.)
Minimum thickness:
1.0 mm (0.039 in.)
If the lining thickness is equal to or less than the minimum, or if severe or
uneven wear is present, replace the shoe.
HINT:
If any of the shoes have to be replaced, replace all of the shoes in order to
maintain even braking.
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.
4. CHECK REAR WHEEL BRAKE CYLINDER ASSEMBLY

a. Check the cylinder bore and piston for rust or scoring.
If necessary, replace the cylinder and piston.
LOAD SENSING PROPORTIONING VALVE > REMOVAL

NOTICE:
surface.
2. DISCONNECT NO. 2 LOAD SENSING SPRING SHACKLE
a. Remove the bolt, collar and 2 cushions.

b. Disconnect the shackle from the rear differential.
3. REMOVE LOAD SENSING PROPORTIONING VALVE ASSEMBLY
a. Using SST, disconnect the 3 brake lines from the valve body.
SST
09023-00101
b. Remove the 3 bolts and valve
LOAD SENSING PROPORTIONING VALVE > INSTALLATION

HINT:
A bolt without a torque specification is shown in the standard bolt chart
1. INSTALL LOAD SENSING PROPORTIONING VALVE ASSEMBLY
a. Install the valve with the 3 bolts.

Torque:
29.4 N*m{ 300 kgf*cm , 22 ft.*lbf }
b. Using SST, connect the 3 brake lines to the valve body.
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.).
2. CONNECT NO. 2 LOAD SENSING SPRING SHACKLE
a. Connect the No. 2 shackle to the rear differential.

b. Install the bolt, collar and 2 cushions.
Torque:
29.4 N*m{ 300 kgf*cm , 22 ft.*lbf }
3. FILL RESERVOIR WITH BRAKE FLUID (for TMT Made LHD)
Fluid:
SAE J1703 or FMVSS No. 116 DOT3
4. FILL RESERVOIR WITH BRAKE FLUID (for TMT Made RHD)
Fluid:
5. FILL RESERVOIR WITH BRAKE FLUID (for TSAM Made LHD)
Fluid:
6. FILL RESERVOIR WITH BRAKE FLUID (for TSAM Made RHD)
Fluid:
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:
HINT:
8. BLEED AIR FROM BRAKE MASTER CYLINDER (for TMT Made RHD)
HINT:
SST
09023-00101
SST
09023-00101
Torque:
HINT:
9. BLEED AIR FROM BRAKE MASTER CYLINDER (for TSAM Made LHD)
HINT:
SST
09023-00101
SST
09023-00101
Torque:
HINT:
10. BLEED AIR FROM BRAKE MASTER CYLINDER (for TSAM Made RHD)
HINT:
SST
09023-00101
SST
09023-00101
Torque:
HINT:
11. BLEED AIR FROM LOAD SENSING VALVE BODY (for TSAM Made LHD)
a. Remove the bleeder plug cap.
b. Connect the vinyl tube to the bleeder plug.

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.
Tighten the bleeder plug.
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)

gone.
f.
Torque:
10.5 N*m{ 107 kgf*cm , 8 ft.*lbf }
13. REMOVE AIR FROM LOAD SENSING VALVE BODY (for TMT Made LHD)

gone.
f.
Torque:
10.5 N*m{ 107 kgf*cm , 8 ft.*lbf }
14. REMOVE AIR FROM LOAD SENSING VALVE BODY (for TMT Made RHD)

gone.
f.
Torque:
10.5 N*m{ 107 kgf*cm , 8 ft.*lbf }
15. BLEED AIR FROM BRAKE LINE (for TMT Made LHD)
b. Connect the vinyl tube to the bleeder plugs.
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)
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)
gone.
f.
Torque:
g. Install the cap.
procedures.
17. BLEED AIR FROM BRAKE LINE (for TSAM Made LHD)
gone.
f.
Torque:
g. Install the cap.
procedures.
18. BLEED AIR FROM BRAKE LINE (for TSAM Made RHD)
gone.
f.
Torque:
g. Install the cap.
procedures.
19. BLEED AIR FROM CLUTCH LINE (for Manual Transmission)

c. Depress the clutch pedal several times, and then loosen the bleeder
plug with the pedal depressed.
d. At the point when fluid stops coming out, tighten the bleeder plug,
and then release the clutch pedal.
e. Repeat the previous 2 steps until all the air in the fluid is
completely bled out.
f.
Torque:
11 N*m{ 112 kgf*cm , 8 ft.*lbf }
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)
a. Check the fluid level and add fluid if necessary.

Fluid:
HINT:
Add fluid to a level between the reservoir's MIN and MAX lines.
21. CHECK BRAKE FLUID LEVEL IN RESERVOIR (for TMT Made RHD)

Fluid:
HINT:
22. CHECK BRAKE FLUID LEVEL IN RESERVOIR (for TSAM Made LHD)

Fluid:
HINT:
23. CHECK BRAKE FLUID LEVEL IN RESERVOIR (for TSAM Made RHD)

Fluid:
HINT:
24. CHECK FOR BRAKE FLUID LEAKAGE
25. CHECK LOAD SENSING PROPORTIONING VALVE ASSEMBLY
a. Set the vehicle to its curb weight.

b. Place weights (as necessary) on the rear deck until the rear axle
load is as shown below.
Standard rear axle load:
Vehicle Type
Specified Condition
2WD Single
Cab
7,845 N (800 kgf,

1,764 lbf)
2WD Extra Cab
8,336 N (850 kgf,

1,874 lbf)
2WD Double
Cab
8,826 N (900 kgf,

1,984 lbf)
4WD Single
Cab
9,807 N (1,000 kgf,

2,205 lbf)
4WD Double
Cab
10,297 N (1,050
kgf, 2,315 lbf)
Pre-runner
Single Cab
9,807 N (1,000 kgf,

2,205 lbf)
Pre-runner
Double Cab
10,297 N (1,050
kgf, 2,315 lbf)
NOTICE:
Be sure that the vehicle is on a level surface before

starting the procedure.
When placing the weights on the vehicle, first place

approximately 60 kg (132 lb) above the specification.
Then remove weights as necessary to adjust the load.
c. Set SST, and bleed air from the brake system.

SST
09709-29018
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
5,260 +-490 kPa (53.6

+-5.0 kgf/cm2, 762 +71 psi)
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.
26. ADJUST LOAD SENSING PROPORTIONING VALVE ASSEMBLY
a. Adjust the length of the No. 2 shackle.

For lower pressure - Lengthen "A"
For higher pressure - Shorten "A"
Standard initial set ("A" length):
Specified
Vehicle Type
Condition
2WD
120 mm (4.764
in.)
4WD and Prerunner
190 mm (7.543
in.)
Standard adjusting ("A" length):

Vehicle Type
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
For 1 mm (0.039 in.)

of "A" length
2WD
140 kPa (1.4 kgf/cm2,

20.5 psi)
4WD and Pre- 120 kPa (1.2 kgf/cm2,

runner
17.6 psi)
b. If the pressure cannot be adjusted by the No. 2 shackle, raise or

lower the valve body.
For lower pressure - Lower the valve body
For higher pressure - Raise the valve body
c. Tighten the nuts.
Torque:
12.5 N*m{ 130 kgf*cm , 9 ft.*lbf }
d. Adjust the length of the No. 2 shackle again.
HINT:
If it cannot be adjusted, check the valve body.

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SERVICIO NACIONAL DE APRENDIZAJE

CENTRO DE TECNOLOGIAS DEL TRANSPORTE

a. Check the pedal height.

152.9 to 162.9 mm (6.020

154.1 to 164.1 mm (6.067

156.9 to 166.9 mm (6.177

158.1 to 168.1 mm (6.224

b. Adjust the pedal height.

Disconnect the connector from the stop light switch.

Loosen the push rod clevis lock nut.

Turn the switch a quarter turn clockwise.

Connect the connector to the switch.

2. CHECK BRAKE PEDAL FREE PLAY

3. CHECK BRAKE PEDAL RESERVE DISTANCE

a. Release the parking brake lever. Start the engine.

RHD (4WD and

If the distance is not as specified, troubleshoot the brake system.

2. DRAIN BRAKE FLUID

3. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY

a. for Manual Transmission:

d. Remove the 2 nuts and brake tube way.

Remove the O-ring from the master cylinder.

4. REMOVE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY

CHECK AND ADJUST BRAKE BOOSTER PUSH ROD

b. Turn SST upside down, and then set it on the booster.

BRAKE BOOSTER (for TSAM Made LHD) > ON-VEHICLE

2. CHECK BRAKE VACUUM CHECK VALVE ASSEMBLY

a. Check the check valve.

Slide the clip and disconnect the vacuum hose.

VACUUM PUMP (DIESEL Engine) > INSPECTION

2. CHECK VACUUM PUMP HOUSING

a. Check the inside surface of the housing for scoring.

FRONT BRAKE > REMOVAL

Use the same procedures for the LH side and RH side.

1. REMOVE FRONT WHEEL

2. DRAIN BRAKE FLUID

3. REMOVE FRONT DISC BRAKE ANTI-RATTLE SPRING

a. Remove the 2 clips. Then remove the 2 pins.

4. REMOVE FRONT DISC BRAKE PAD

5. REMOVE FRONT ANTI SQUEAL SHIM KIT

6. REMOVE FRONT NO. 1 WHEEL CYLINDER TUBE LH

7. REMOVE DISC BRAKE CYLINDER ASSEMBLY LH

FRONT BRAKE () > INSPECTION

2. CHECK PAD LINING THICKNESS

a. Using a ruler, measure the pad lining thickness.

3. CHECK DISC THICKNESS

REAR BRAKE () > REMOVAL

Use the same procedures for the LH side and RH side.

1. CHECK BRAKE SHOE LINING THICKNESS

2. REMOVE REAR WHEEL

3. DRAIN BRAKE FLUID

4. REMOVE REAR BRAKE DRUM SUB-ASSEMBLY

REAR BRAKE () > INSPECTION

2. CHECK BRAKE SHOE LINING THICKNESS

a. Using a ruler, measure the thickness of the shoe lining.

4. CHECK REAR WHEEL BRAKE CYLINDER ASSEMBLY

LOAD SENSING PROPORTIONING VALVE > REMOVAL

1. DRAIN BRAKE FLUID

2. DISCONNECT NO. 2 LOAD SENSING SPRING SHACKLE

a. Remove the bolt, collar and 2 cushions.

3. REMOVE LOAD SENSING PROPORTIONING VALVE ASSEMBLY

LOAD SENSING PROPORTIONING VALVE > INSTALLATION

A bolt without a torque specification is shown in the standard bolt chart

1. INSTALL LOAD SENSING PROPORTIONING VALVE ASSEMBLY