Chapter 11: Brake System
Covers brake specifications, pedal adjustment, disk/drum inspection, pedal linkage (M/T and A/T), master cylinder/booster, proportioning valve, front disk brake and caliper, rear drum brake and wheel cylinder, the full ABS hydraulic circuit (master cylinder, pump unit, speed sensors, ECU, G-sensor), and the parking brake.
Our truck: VR-grade, 4A30 DOHC turbo, 3A/T automatic, 4WD. Where a section is split by transmission (pedal linkage) or by ABS fitment, the A/T and ABS variants are the ones that apply here — the M/T pedal linkage section is included for completeness only.
Factory note (printed p.263, verbatim): “See ABS Supplement for the complete troubleshooting guide on the ABS system.” — this chapter covers ABS component removal/inspection/replacement; diagnostic trouble-code procedures live in a separate ABS Supplement not present in this scan.
- Brake Specifications — pedal height/travel, disk thickness/run-out, hub run-out, drum diameter, and lining thickness limits.
- Pedal Adjustment — pedal height, stop lamp switch clearance, engagement travel, deck height clearance.
- Disk Rotor & Rear Drum Inspection — disk thickness/run-out and hub run-out measurement; rear lining thickness and drum diameter measurement.
- Brake Pedal Linkage: M/T Vehicle — not applicable to our truck; included for completeness.
- Brake Pedal Linkage: A/T Vehicle — applies to our truck (3A/T).
- Master Cylinder & Brake Booster Replacement: Standard — removal procedure for both.
- Master Cylinder Overhaul: Standard — exploded view, piston stopper bolt removal.
- Proportioning Valve — remove/replace only, not rebuildable.
- Disk Brake Assembly — hose, caliper, disk removal.
- Caliper Overhaul — piston/seal removal, pad inspection.
- Rear Drum Brakes — full drum brake exploded view.
- Wheel Cylinder — overhaul kit, LH/RH set-replacement guidance.
- ABS Master Cylinder — ABS-vehicle master cylinder overhaul.
- ABS Hydraulic Pump Unit — pump/valve relay, hydraulic line identification.
- ABS Speed Sensor — front/rear pickups, resistance test procedure.
- ABS-ECU Location — placeholder; minimal content survived OCR (see note in file).
- ABS G-Sensor — orientation requirement, voltage test procedure.
- Parking Brake — cable and lever assembly components.