Description & Operation: Warning

1995 Toyota 4Runner SR5
BRAKE SYSTEM 1995-96 BRAKES Toyota - Disc & Drum
BRAKE SYSTEM
1995-96 BRAKES Toyota - Disc & Drum
DESCRIPTION & OPERATION
WARNING: For warnings and procedures regarding vehicles equipped with Anti-Lock
Brake Systems (ABS), see ANTI-LOCK BRAKE SAFETY PRECAUTIONS
article.
Hydraulic brake system uses a tandem master cylinder with a vacuum power assist servo. Vehicles are equipped
with front disc brakes and rear drum brakes standard.
A load-sensing proportioning valve is used to regulate brake pressure between front and rear brakes. Rear
brakes are self-adjusting.
Parking brake lever mechanically activates the rear brakes. A cable applies rear shoes.
BLEEDING BRAKE SYSTEM

BLEEDING PROCEDURES
CAUTION: DO NOT allow reservoir to run dry during brake bleeding procedure. Use
only clean brake fluid. Ensure no dirt or other foreign matter contaminates
brake fluid. DO NOT mix different types of brake fluid, as they may not be
compatible. DO NOT spill brake fluid on vehicle, as it may damage paint. If
brake fluid contacts paint, immediately wash with water.
1. If master cylinder is rebuilt or reservoir is empty, bleed master cylinder first. Bleed wheels in sequence.
Start on wheel with longest hydraulic line, and work toward wheel with shortest hydraulic line.
2. Raise and support vehicle. Ensure brake fluid reservoir is at least half full during bleeding procedure.
Connect one end of transparent vinyl tube to bleeder screw. Submerge other end of tube in a container
half filled with clean brake fluid.
3. Have an assistant depress brake pedal several times and hold in depressed position. Loosen bleeder screw,
and drain fluid into container. Tighten bleeder screw.
NOTE: Ensure brake pedal remains depressed until bleeder screw is tightened.
4. Refill brake fluid reservoir as necessary. Repeat step 3) until air is no longer discharged. Tighten bleeder
screw to 74 INCH lbs. (8 N.m). Ensure fluid leakage is not present. Add fluid to reservoir. Repeat
procedure for remaining wheels.
ADJUSTMENTS
BRAKE PEDAL HEIGHT
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10:21:45 a.m. Page 1 © 2011 Mitchell Repair Information Company, LLC.
1. Brake pedal height is measured from face of pedal pad to asphalt sheet under carpet. To adjust clearance,
loosen stoplight switch and lock nut on brake push rod. See Fig. 1 .
2. Adjust pedal height by turning push rod. See BRAKE PEDAL SPECIFICATIONS table for correct
specification. After setting pedal height, tighten lock nut on push rod. Adjust stoplight switch and tighten
switch lock nut. See STOPLIGHT SWITCH .
Fig. 1: Measuring Brake Pedal Height & Free Play

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
BRAKE PEDAL SPECIFICATIONS

Application Free Play In. (mm) Pedal Height In. (mm)
1995 .12-.24 (3.0-6.0) 5.5-5.9 (140-150)
1996 .12-.24 (3.0-6.0) 6.2-6.6 (158-168)
BRAKE PEDAL FREE PLAY
1. Brake pedal free play is distance brake pedal travels before feeling resistance with engine stopped. To
check pedal free play, depress brake pedal several times to exhaust vacuum from servo.
2. Depress pedal and measure travel until initial resistance is felt. See BRAKE PEDAL
SPECIFICATIONS . If free play is not within specification, adjust by turning push rod. See Fig. 1 .
BRAKE PEDAL RESERVE DISTANCE

lunes, 08 de mayo de 2017 10:21:45 a.m. Page 2 © 2011 Mitchell Repair Information Company, LLC.
1. Pedal reserve distance is measured from face of pedal pad to asphalt sheet under carpet with brakes
applied. Measure reserve distance with engine running and weight of 110 lbs. (50 kg) applied against
pedal.
2. If measured reserve distance is less than specification, inspect brake system. See BRAKE PEDAL
MINIMUM RESERVE DISTANCE SPECIFICATIONS table.
BRAKE PEDAL MINIMUM RESERVE DISTANCE SPECIFICATIONS

Application In. (mm)
1995
With 4WAL Brakes 2.55 (65)
Without 4WAL Brakes 2.76 (70)
1996 2.83 (72)
LSPV (LOAD-SENSING PROPORTIONING VALVE) & BPV (BY-PASS VALVE)
NOTE: See LOAD-SENSING PROPORTIONING VALVE (LSPV) & BY-PASS VALVE (BPV)
under TESTING.
PARKING BRAKE
NOTE: Rear brakes must be correctly adjusted before adjusting parking brake. See
REAR BRAKE DRUM under REMOVAL & INSTALLATION.
Lever Stroke Adjustment
1. Pull on parking brake lever with weight of 44 lbs. (20 kg) to check parking brake adjustment. Count
number of notches (clicks) until parking brake is fully applied. See PARKING BRAKE LEVER
STROKE SPECIFICATIONS table. Adjust parking brake if travel is not within specification.
PARKING BRAKE LEVER STROKE SPECIFICATIONS

Application Notches
1995 13-19
1996 7-9
2. On 1996 models, Remove center console or parking brake lever boot to uncover base of lever. Loosen
adjusting cap. Turn adjusting nut on cable until lever travel is correct. Tighten adjusting cap. Install
console or boot.
3. On 1995 models, Release parking brake. From beneath vehicle, loosen lock nut on equalizer bar pull rod.
Turn adjuster nut until lever travel is correct. Tighten lock nut.
BRAKE BOOSTER PUSH ROD
1. Install Adjusting Gauge (09737-00010) on master cylinder with master cylinder gasket in place. Lower
adjusting gauge pin until pin slightly touches master cylinder piston. Perform STEP 1. See Fig. 2 . Turn
adjusting gauge upside down and install on power brake unit.

2. Measure clearance between power brake unit push rod and adjusting gauge pin head. Measured clearance
should be zero. Perform STEP 2. See Fig. 2 . If clearance is not zero, adjust brake booster push rod length
until push rod lightly touches adjusting gauge pin head.
Fig. 2: Adjusting Brake Booster Push Rod

REAR DRUM BRAKE SHOES
NOTE: All rear drum brakes have a self-adjuster which is activated when brake pedal is
applied with vehicle traveling in reverse.
To set initial lining-to-drum clearance, raise and support rear of vehicle. Release parking brake. Remove rear
wheels and brake drums. Measure brake drum inside diameter and brake lining diameter. Measured clearance
between linings and braking surface of drum should be .024" (.60 mm). Turn brake adjuster to obtain specified
clearance. Install brake drum and wheel and adjust brakes (if necessary).
STOPLIGHT SWITCH
Remove lower instrument panel and air duct (if necessary). Loosen lock nuts. Turn switch until clearance
between threaded end of switch and pedal stop is .02-.09" (.5-2.3 mm). See Fig. 1 . Check brake pedal height
and brakelight operation.
TESTING
POWER BRAKE UNIT

Functional Test
1. Start engine. Turn ignition off. Depress brake pedal several times. Depress pedal firmly and hold pressure
for 15 seconds. If pedal sinks, master cylinder, wheel cylinder, caliper or brakeline is faulty.
2. Start engine with pedal depressed. If pedal sinks slightly, vacuum unit is working properly. If pedal
height does not vary, booster or check valve is faulty. Replace as necessary.
Leak Test
1. Depress brake pedal with engine running. Turn ignition off. If pedal height does not vary while depressed
for 30 seconds, vacuum booster is okay. If pedal height changes, check for air leaks.
2. With engine stopped, depress brake pedal several times using normal pressure. Pedal should be low when
first depressed. On consecutive applications, pedal height should gradually rise. If pedal height does not
increase, check for air leaks.
LOAD-SENSING PROPORTIONING VALVE (LSPV) & BY-PASS VALVE (BPV)
1995
1. For testing purposes, rear axle is loaded to a specified weight. Set total rear axle weight to specified
amount. See LSPV REAR AXLE TEST WEIGHT .
NOTE: DO NOT depress brake pedal more than once or release pedal while
setting pressure on front gauge.
2. Attach Pressure Gauge Set (09709-29017) to front caliper and rear wheel cylinder or caliper. Bleed air
from system. See BLEEDING BRAKE SYSTEM . Depress brake pedal until front pressure is as
specified. See LSPV PRESSURE SPECIFICATIONS table. Wait 2 seconds and record rear pressure
reading.
LSPV REAR AXLE TEST WEIGHT

Application Lbs. (kg)
1995 2310 (1048)
1996 2037 (1048)
LSPV PRESSURE SPECIFICATIONS

Front Pressure psi Rear Pressure psi
Application (kg/cm2 ) (kg/cm2 )
1995 1138 (80) 686-828 (48-58)
1996 996 (70) 427-540 (30-38)
3. Adjust rear pressure by changing length of No. 2 shackle (if necessary). See Fig. 3 . To increase rear
pressure reading, increase distance "A". To decrease rear pressure reading, decrease distance "A".
4. Repeat pressure tests after adjusting shackle length. If rear pressures fail specification after adjustment,
reposition valve body. Raise valve body if rear pressures are too high, lower valve body if rear pressures
are too low.

5. Ensure No. 2 shackle length is within adjustment range. If shackle is removed or replaced, adjust No. 2
shackle to standard length. See NO. 2 SHACKLE LENGTH SPECIFICATIONS table.
Fig. 3: Measuring LSPV No. 2 Shackle Length

NO. 2 SHACKLE LENGTH SPECIFICATIONS

Standard Length Adjustment Range
Application In. (mm) In. (mm)
1995 3.07 (78) 2.68-3.46 (68-88)

6. If pressures cannot be adjusted to specification, check valve housing. Position valve body in uppermost
position. Apply brakes and record rear brake pressures. See VALVE BODY ADJUSTMENT PRESSURE
SPECIFICATIONS table. If measured value does not meet specification, replace valve assembly.
VALVE BODY ADJUSTMENT PRESSURE SPECIFICATIONS

Front Pressure psi Rear Pressure psi
Application (kg/cm2 ) (kg/cm2 )
1995
1st Reading 285 (20) 285 (20)
2nd Reading 570 (40) 313-370 (22-26)
3rd Reading 998 (70) 378-478 (26.5-
33.5)
1996 (1) 996 (70) 320-420 (22.5-29.5)
(1) For 1996 models, only one adjustment pressure is indicated.
1996
1. For testing purposes, rear axle is loaded to a specified weight. Set total rear axle weight to specified
amount. See LSPV REAR AXLE TEST WEIGHT .
NOTE: DO NOT depress brake pedal more than once or release pedal while
setting pressure on front gauge.
2. Attach Pressure Gauge Set (09709-29017) to front caliper and rear wheel cylinder. Bleed air from system.
See BLEEDING BRAKE SYSTEM . Depress brake pedal until front pressure is as specified. See LSPV
PRESSURE SPECIFICATIONS . Wait 2 seconds and record rear pressure reading.
3. Adjust rear pressure by changing length of spring. See Fig. 4 . To increase rear pressure reading, decrease
distance "A". To de crease rear pressure reading, increase distance "A". If valve cannot be adjusted to
specification, replace valve assembly.
NOTE: For pressure change of 13 psi (.91 kg/cm2 ) on rear brakes, turn adjustment nut
one complete turn (360 degrees).

Fig. 4: Measuring LSPV Spring Shaft Length (1996)

REMOVAL & INSTALLATION
NOTE: Location and number of anti-rattle springs, anti-squeal shims, pad support and
guide plates vary between models. Note component locations during removal
process for reassembly reference.
FRONT DISC BRAKE PADS

NOTE: Pushing piston into caliper bore will force fluid back into master cylinder
reservoir. Remove reservoir cap when compressing caliper piston.
Removal
Loosen master cylinder reservoir cap. Raise vehicle and remove wheels. Remove clip, 2 pins and anti-rattle
spring. Remove pads and shims. See Fig. 5 .
NOTE: Always change pads on one wheel at a time. Opposite piston may be pressed
out by fluid pressure.
Fig. 5: Exploded View Of Front Brake Caliper Assembly

Installation
Seat pistons using a hammer handle or equivalent. Slide NEW pads and anti-rattle shims into caliper. Install
retaining pins and anti-rattle spring. Install clip into retaining pin holes. Check reservoir fluid level.
FRONT BRAKE CALIPER
Removal & Installation
1. Raise vehicle and remove wheels. Disconnect flexible brake hose from caliper. Plug hose to prevent fluid
spillage. Remove caliper mounting bolts or slide pins as necessary.
2. On models with fixed main pin, pivot caliper up to clear edge of rotor. Slide caliper off main pin. On all
other models, remove caliper from knuckle or torque plate. To install, reverse removal procedure. On
units with fixed main pin, install boot end in groove of main pin.
FRONT BRAKE ROTOR
Removal
1. Raise vehicle and remove wheels. Disconnect brakeline from caliper (if necessary). Remove caliper.
2. On models with free wheeling hub, set control handle to FREE position. On all models, remove hub
cover, bolt/washer and hub body. Use tapered punch to open slits of conical washers. Remove axle shaft
snap ring (if equipped).
3. Straighten tabs of outer lock washer. Using Spindle Socket (09607-60020), remove lock nut, lock washer
and adjusting nut. Remove thrust washer and outer bearing. Remove axle hub and rotor. Remove grease
seal and inner bearing. Press hub bolts out of axle hub. Remove retaining bolts, and separate rotor from
hub.
Installation
To install, reverse removal procedure. Adjust wheel bearings. See appropriate article:
SUSPENSION - FRONT - 2WD .

SUSPENSION - FRONT - 4WD .
Tighten all bolts to specification. See TORQUE SPECIFICATIONS .
REAR BRAKE DRUM
Removal
Ensure parking brake is released. Raise and support vehicle. Remove wheel. Remove set screws from brake
drum (if equipped). Pull drum from axle flange. It may be necessary to loosen brake shoe adjuster before
removing drum.

Installation
Measure inside diameter of brake drum and diameter of brake shoes. Turn brake adjuster until difference
between diameters is .024" (.60 mm). Install brake drum and adjust brakes, if necessary.
REAR DRUM BRAKE SHOES
Removal
Remove brake drum, tension spring and hold-down springs. See Fig. 6 . Remove tension spring from bell crank.
Remove brake shoes and disengage parking brake lever.
Fig. 6: Exploded View Of Typical Rear Drum Brakes

Installation
Position brake shoes over wheel cylinders with front return spring hooked on inner side of shoe. Install hold-
down springs. To complete installation, reverse removal procedures. Adjust brake shoes.

REAR WHEEL CYLINDER
With brake drum and shoes removed, disconnect hydraulic line from wheel cylinder. Remove mounting bolts
and remove wheel cylinder. To install, reverse removal procedure. Adjust brakes and bleed system. See
BLEEDING BRAKE SYSTEM .
REAR AXLE BEARING & OIL SEAL
Removal
1. Remove wheel and brake drum. Disconnect line at wheel cylinder. Disconnect parking brake cable.
Remove backing plate mounting nuts. Pull out axle shaft and backing plate together. Remove snap ring
from axle shaft.
2. Attach Pressing Tube (09521-25011) to rear of backing plate. Press axle shaft from backing plate. Using
slide hammer with inside puller, remove outer oil seal. Support backing plate around bearing. Using press
with bearing driver, press bearing out of bearing case.
3. If bearing case is worn or damaged, put nuts on serration bolts and drive bolts out with hammer. Using
slide hammer with inside puller, remove inner oil seal from axle shaft. Clean all parts before
reinstallation.
Installation
1. Place backing plate on NEW bearing case. Using 2 sockets as adapters, press serration bolts into place.
Flat side of bearing case and 2 long serration bolts should be on upper side of backing plate. Using press,
bearing driver and support for backing plate, press NEW bearing into case.
2. Using seal driver, install NEW oil seal into bearing case. Install backing plate and bearing retainer onto
axle shaft. Using press and adapter for backing plate and bearing case, press axle shaft into backing plate
and bearing case.
3. Install NEW snap ring to axle shaft. Use seal driver to install seal in housing. Coat oil seal lips with
grease before final installation. Install rear axle shaft in housing. Replace backing plate nuts and tighten
specification. See TORQUE SPECIFICATIONS .
4. Connect brakeline to wheel cylinder. Install drum and wheel. Fill differential with gear oil. Connect
parking brake cable to equalizer, and install clip and clamp bolt to frame. Bleed brake system. See
BLEEDING BRAKE SYSTEM .
MASTER CYLINDER
Removal
Unplug sensor lead. Drain brake fluid from reservoir. Disconnect and plug hydraulic lines. Remove master
cylinder-to-power brake unit nuts. Remove master cylinder.
Installation

If master cylinder has been overhauled or replaced, check and adjust power brake unit push rod. See BRAKE
BOOSTER PUSH ROD under ADJUSTMENTS. To install, reverse removal procedure. Bleed brake system.
See BLEEDING BRAKE SYSTEM .
POWER BRAKE UNIT
Remove master cylinder assembly from vehicle. See MASTER CYLINDER . Disconnect vacuum hose.
Disconnect push rod clevis at brake pedal. Remove power brake unit from vehicle. To install, reverse removal
procedure.
LSPV & BPV (LOAD-SENSING PROPORTIONING VALVE & BY-PASS VALVE)
Removal (1995)
Raise and support vehicle. Disconnect No. 2 shackle from bracket. See Fig. 7 . Disconnect and plug hydraulic
lines from LSPV. Remove clip from brake hose. Remove mounting bolts from valve bracket, and remove LSPV
assembly. Separate valve body from bracket.
Installation
1. To install, reverse removal procedure. Apply rubber grease to all rubbing areas. Install NEW rubber plate
on valve body side of spring.
2. Adjust length of upper and lower shackle to original height. See LOAD-SENSING PROPORTIONING
VALVE (LSPV) & BY-PASS VALVE (BPV) under TESTING. Bleed hydraulic system. See
BLEEDING BRAKE SYSTEM . Check LSPV brake pressures.

Fig. 7: Exploded View Of LSPV (1995)

Removal & Installation (1996)
Raise and support vehicle. Disconnect brake lines. Remove lock nut and disconnect adjusting bolt from rear
suspension arm. Remove adjusting spring. See Fig. 4 . Remove 2 mounting bolts and LSPV. To install, reverse
removal procedure. Adjust LSPV spring length as necessary. See LOAD-SENSING PROPORTIONING
VALVE (LSPV) & BY-PASS VALVE (BPV) under TESTING. Bleed hydraulic system. See BLEEDING
BRAKE SYSTEM . Check LSPV brake pressures.
OVERHAUL
NOTE: When overhauling caliper, if piston bores are pitted or scored beyond repair by
light honing, replace entire assembly.
FRONT BRAKE CALIPER
NOTE: When overhauling front brake calipers, see Fig. 5 , Fig. 7 or Fig. 8 .
MASTER CYLINDER
NOTE: For exploded view of master cylinder assembly, see Fig. 8 .
Fig. 8: Exploded View Of Master Cylinder Assembly (Typical)

LSPV & BPV (LOAD-SENSING PROPORTIONING VALVE & BY-PASS VALVE)

NOTE: When overhauling LSPV and BPV, see Fig. 7 .
DISC BRAKE SPECIFICATIONS

DISC BRAKE SPECIFICATIONS
1995
Standard Disc Thickness .984 (25.00)
Minimum Refinish Disc Thickness .906 (23.00)
Maximum Disc Runout .0035 (.090)
Standard Pad Thickness .374 (9.50)
Minimum Pad Thickness .039 (1.00)
1996
Standard Disc Thickness .867 (22.00)
Minimum Refinish Disc Thickness .787 (20.00)
Maximum Disc Runout .0028 (.070)
Standard Pad Thickness .453 (11.50)
Minimum Pad Thickness .039 (1.00)
DRUM BRAKE SPECIFICATIONS

DRUM BRAKE SPECIFICATIONS
Standard Diameter 11.61 (295.0)
Maximum Refinish Diameter 11.69 (297.0)
Standard Lining Thickness .236 (6.00)
Minimum Lining Thickness .039 (1.00)
Brake Shoe Clearance .024 (.60)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
Brake Hose-To-Caliper 11 (15)
Caliper Mounting Bolts/Slide Pins 91 (123)
Hub-To-Rotor Bolts (1995) 47 (64)
LSPV Mounting Bolts
1995 11 (15)
1996 22 (29)
Master Cylinder Outlet Fittings 11 (15)
Rear Axle Retainer & Backing Plate Nuts 48 (66)
Wheel Lug Nuts

1995 76 (103)
1996 81 (110)
INCH Lbs. (N.m)
Brake Bleeder Screw 97 (11)
LSPV Adjusting Screws/Nuts 115 (13)
Master Cylinder Piston Stopper Bolt 89 (10)
Master Cylinder-To-Booster Nuts 115 (13)


Description & Operation: Warning

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1995 Toyota 4Runner SR5

BRAKE SYSTEM 1995-96 BRAKES Toyota - Disc & Drum

1995-96 BRAKES Toyota - Disc & Drum

DESCRIPTION & OPERATION

BLEEDING BRAKE SYSTEM

Fig. 1: Measuring Brake Pedal Height & Free Play

BRAKE PEDAL SPECIFICATIONS

BRAKE PEDAL FREE PLAY

BRAKE PEDAL RESERVE DISTANCE

GARCIA - Servicios Automotrices 56902755

BRAKE PEDAL MINIMUM RESERVE DISTANCE SPECIFICATIONS

LSPV (LOAD-SENSING PROPORTIONING VALVE) & BPV (BY-PASS VALVE)

Lever Stroke Adjustment

PARKING BRAKE LEVER STROKE SPECIFICATIONS

BRAKE BOOSTER PUSH ROD

adjusting gauge upside down and install on power brake unit.

Fig. 2: Adjusting Brake Booster Push Rod

REAR DRUM BRAKE SHOES

GARCIA - Servicios Automotrices 56902755

LOAD-SENSING PROPORTIONING VALVE (LSPV) & BY-PASS VALVE (BPV)

LSPV REAR AXLE TEST WEIGHT

LSPV PRESSURE SPECIFICATIONS

are too low.

Fig. 3: Measuring LSPV No. 2 Shackle Length

NO. 2 SHACKLE LENGTH SPECIFICATIONS

GARCIA - Servicios Automotrices 56902755

VALVE BODY ADJUSTMENT PRESSURE SPECIFICATIONS

GARCIA - Servicios Automotrices 56902755

Fig. 4: Measuring LSPV Spring Shaft Length (1996)

REMOVAL & INSTALLATION

FRONT DISC BRAKE PADS

Fig. 5: Exploded View Of Front Brake Caliper Assembly

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

FRONT BRAKE CALIPER

Removal & Installation

FRONT BRAKE ROTOR

SUSPENSION - FRONT - 2WD .

Tighten all bolts to specification. See TORQUE SPECIFICATIONS .

REAR BRAKE DRUM

GARCIA - Servicios Automotrices 56902755

REAR DRUM BRAKE SHOES

Fig. 6: Exploded View Of Typical Rear Drum Brakes

GARCIA - Servicios Automotrices 56902755

REAR WHEEL CYLINDER

Removal & Installation

REAR AXLE BEARING & OIL SEAL

GARCIA - Servicios Automotrices 56902755

POWER BRAKE UNIT

Removal & Installation

LSPV & BPV (LOAD-SENSING PROPORTIONING VALVE & BY-PASS VALVE)

GARCIA - Servicios Automotrices 56902755

Fig. 7: Exploded View Of LSPV (1995)

Removal & Installation (1996)

BRAKE SYSTEM . Check LSPV brake pressures.

FRONT BRAKE CALIPER

NOTE: For exploded view of master cylinder assembly, see Fig. 8 .

Fig. 8: Exploded View Of Master Cylinder Assembly (Typical)

LSPV & BPV (LOAD-SENSING PROPORTIONING VALVE & BY-PASS VALVE)

NOTE: When overhauling LSPV and BPV, see Fig. 7 .

DISC BRAKE SPECIFICATIONS

DRUM BRAKE SPECIFICATIONS

Wheel Lug Nuts

GARCIA - Servicios Automotrices 56902755