GSIC - Global Service Information Center

# LOAD SENSING PROPORTIONING VALVE > INSTALLATION

## for Preparation Click here

HINT:

  A bolt without a torque specification is shown in the standard bolt chart (Click here).

1. INSTALL LOAD SENSING PROPORTIONING VALVE ASSEMBLY

1. Install the valve with the 3 bolts.

   Torque:
     29.4 N*m{ 300 kgf*cm , 22 ft.*lbf }

1. 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

1. Connect the No. 2 shackle to the rear differential.

1. Install the bolt, collar and 2 cushions.

   Torque:
     29.4 N*m{ 300 kgf*cm , 22 ft.*lbf }

3. FILL RESERVOIR WITH BRAKE FLUID

Fluid:
  SAE J1703 or FMVSS No. 116 DOT3

4. BLEED AIR FROM BRAKE MASTER CYLINDER

HINT:

  If the master cylinder has been disassembled or if the reservoir becomes empty, bleed air from the master cylinder.

1. Using SST, disconnect the 2 brake lines from the master cylinder.

   SST
     09023-00101

1. Slowly depress and hold the brake pedal.

1. Cover the outer holes with your finger, and release the pedal.

1. Repeat the 2 previous steps 3 or 4 times.

1. Using SST, connect the 2 brake lines to the master cylinder.

   SST
     09023-00101

   Torque:
     15.2 N*m{ 155 kgf*cm , 11 ft.*lbf } without SST
     14 N*m{ 143 kgf*cm , 10 ft.*lbf } with SST

   HINT:
     Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

5. BLEED AIR FROM BRAKE LINE

1. Remove the bleeder plug cap.

1. Connect the vinyl tube to the bleeder plugs.

1. Depress the pedal several times, and then loosen the bleeder plug with the pedal depressed.

1. When fluid stops coming out, immediately tighten the bleeder plug. Then release the pedal.

1. Repeat the 2 previous steps until all the air in the brake fluid is gone.

1. Tighten the bleeder plug.

   Torque:
     10.8 N*m{ 110 kgf*cm , 8 ft.*lbf } for front brake
     11 N*m{ 112 kgf*cm , 8 ft.*lbf } for rear brake (2WD)
     10 N*m{ 102 kgf*cm , 7 ft.*lbf } for rear brake (4WD)

1. Install the cap.

1. Bleed air from the brake line for each wheel by repeating the above procedures.

6. BLEED AIR FROM CLUTCH LINE (M/T)

1. Remove the bleeder plug cap.

1. Connect the vinyl tube to the bleeder plug.

1. Depress the clutch pedal several times, and then loosen the bleeder plug with the pedal depressed.

1. At the point when fluid stops coming out, tighten the bleeder plug, and then release the clutch pedal.

1. Repeat the previous 2 steps until all the air in the fluid is completely bled out.

1. Tighten the bleeder plug.

   Torque:
     11 N*m{ 112 kgf*cm , 8 ft.*lbf }

1. Install the bleeder plug cap.

1. Check that all the air has been bled out of the clutch line.

7. CHECK BRAKE FLUID LEVEL IN RESERVOIR

1. Check the fluid level and add fluid if necessary.

   Fluid:
     SAE J1703 or FMVSS No. 116 DOT3

   HINT:
     Add fluid to a level between the reservoir's MIN and MAX lines.

8. CHECK FOR BRAKE FLUID LEAKAGE

9. CHECK LOAD SENSING PROPORTIONING VALVE ASSEMBLY

1. Set the vehicle to its curb weight.

1. Place weights (as necessary) on the rear deck until the rear axle load is shown below.

   Standard:

     Vehicle Type | Rear Axle Load
     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 | 9,807 N (1,000 kgf, 2,205 lbf)

   NOTICE:
   1. Be sure that the vehicle is on a level surface before starting the procedure.
   2. 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.

1. Set SST, and bleed air from the brake system.

   SST
     09709-29018

1. Raise the front brake fluid pressure to 10,000 kPa (107.6 kgf/cm2, 1,450 psi) when the brake pedal is depressed, and measure the rear brake fluid pressure.

   Standard:

     Vehicle Type | Rear Brake Fluid Pressure
     2WD | 5,260 +- 490 kPa (53.6 +- 5.0 kgf/cm2, 762 +- 71 psi)
     4WD | 4,450 +- 490 kPa (45.4 +- 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.

10. ADJUST LOAD SENSING PROPORTIONING VALVE ASSEMBLY

1. Adjust the length of the No. 2 shackle
   For lower pressure - Lengthen "A"
   For higher pressure - Shorten "A"

   Initial set:

     Vehicle Type | "A" length
     2WD | 120 mm (4.764 in.)
     4WD | 190 mm (7.543 in.)

   Adjusting:

     Vehicle Type | "A" length
     2WD | 114 to 126 mm (4.526 to 5.002 in.)
     4WD | 184 to 196 mm (7.305 to 7.781 in.)

   HINT:
     The rear fluid pressure changes to the value on the table below by adjusting the length of "A".

   Vehicle Type | For 1 mm (0.039 in.) of the "A" length
   2WD | 140 kPa (1.4 kgf/cm2, 20.5 psi)
   4WD | 120 kPa (1.2 kgf/cm2, 17.6 psi)

1. 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

1. Tighten the nuts.

   Torque:
     12.5 N*m{ 130 kgf*cm , 9 ft.*lbf }

1. Adjust the length of the No. 2 shackle again.

   HINT:
     If it cannot be adjusted, check the valve body.