CHASSIS-BRAKE CH-75

BRAKE

g DESCRIPTION

General

The new Hilux has a brake system with the following specifications:

Drive Type 2WD 4WD, 2WD PreRunner

Front Brake Type Ventilated Disc 

Rear Brake Type Leading-Trailing Drum 
Brake Control Valve LSP & BV 
Parking Brake Center Lever Type 
Brake Control System ABS* 

* : The provision (standard or option) varies by destination and model (refer to Equipment List on page
MO-30).

271CH49
CH-76 CHASSIS-BRAKE
 CHASSIS-BRAKE CH-77

g Specifications g
Drive Type 2WD 4WD, 2WD PreRunner
Tandem
Tandem
Master Type (Lockheed + Lockheed)
(Lockheed + Lockheed)
Cylinder (Portless + Lockheed)*2
Diameter mm (in.) 20.64 (0.81) 
Brake Type Single 
Booster Size in. 3
9* / 10* 4

Caliper Type Floating Opposed
49 (7.6)*6
Pad Area cm2 (in.2) 50 (7.75)
50 (7.75)*7
Front
Brake Wheel Cylinder Dia. 60.33 (2.38)*6
42.85 (1.69)  2
mm (in.) 60.03 (2.36)*7
Rotor Size (D  T)*1 255  28 (10.04  1.1)*6
297  25 (11.69  0.98)
mm (in.) 257  28 (10.11  1.1)*7
Lining Area cm (in.2)
2
122 (18.9) x 2 141 (21.9) x 2
Rear Wheel Cylinder Dia.
23.81 (0.94) 22.22 (0.87)
Brake mm (in.)
Drum Inner Dia.
254 (10) 295 (11.61)
mm (in.)
Type Drum 
Parking
Brake Drum Inner Dia.
254 (10) 295 (11.61)
mm (in.)
Brake Actuator Manufacturer* 5
ADVICS 

*1: D: Outer Diameter, T: Thickness

*2 : Central and South American models
*3 : Diesel engine models for Thailand, Philippines, Malaysia, Australia and General Countries
*4 : Gasoline engine models for Thailand, Philippines, Malaysia, Australia and General Countries /
models for Central and South America
*5 : Only for with ABS model
*6 : Models for Thailand, Philippines, Malaysia, Australia and General Countries
*7 : Models for Central and South America
CH-78 CHASSIS-BRAKE

g BRAKE CONTROL SYSTEM (ABS)

1. General

The brake control system (ABS) of new Hilux has a following function:

Function Outline

ABS The ABS helps prevent the wheels from locking when the brakes are
(Anti-lock Brake System) applied firmly or when braking on a slippery surface.

Service Tip
When brake control system is activated, the brake pedal could shudder, which is a normal occurrence of the
system in operation and should not be considered a malfunction.

gSystem Diagramg

Stop Light Switch

Brake
Actuator
Speed Speed
Sensors Skid Sensors
Control
ECU

DLC3 ABS Warning Light

4WD Detection Switch*1

Deceleration Sensor*3
A.D.D. Detection Switch*2

271CH50

*1 : 4WD model
*2 : 4WD with A.D.D. model
*3 : 4WD and PreRunner model
CHASSIS-BRAKE CH-79
CH-80 CHASSIS-BRAKE

2. Layout of Main Components

ABS Warning Light

Brake System
Warning Light

Deceleration
Stop Light Switch Sensor*

DLC3

Parking Brake Switch

Reservoir Tank
 Brake Fluid Level
Warning Switch

Speed Sensors

Brake Actuator
 Skid Control ECU
271CH51
Speed Sensors

LHD Model
*: Only for the 4WD and 2WD PreRunner models.
 CHASSIS-BRAKE CH-81

3. Function of Main Components

Components Function

Changes the fluid path based on the signals from the skid control ECU
Brake Actuator during the operation of the ABS, in order to control the fluid pressure
that is applied to the wheel cylinders.
Skid Control Judges the vehicle driving condition based on signals from each sensor,
ECU and sends brake control signals to the brake actuator.
Combination ABS Warning Lights up to alert the driver when the skid control ECU detects a
Meter Light malfunction in the ABS.
Speed Sensor (FL, FR, RL, RR) Detects the wheel speed of each wheels.
Deceleration Sensor*1 Detects the vehicle’s acceleration in the forward, and reward.
Stop Light Switch Detects the brake pedal depressing condition.
Parking Brake Switch Detects when the parking brake lever is pulled up.
L4 Position
Detects the L4 position condition.
Switch
4WD A.D.D. Detection
Detects the A.D.D. shift actuator operating condition.
Model Switch*2
4WD Position
Detects the 4WD position condition.
Switch*3

*1 : Only for the 4WD and 2WD PreRunner models.

*2 : with A.D.D. (Automatic Disconnection Differential) models.
*3 : without A.D.D. models.

4. Brake Actuator

General

A brake actuator with an integrated skid control Skid Control ECU

ECU has been adopted.

Actuator
Portion 271CH52
CH-82 CHASSIS-BRAKE
 CHASSIS-BRAKE CH-83

Actuator Portion

The brake actuator consists of 6 two-position solenoid valves, 1 motor, 2 pumps and 2 reservoirs. The 6
two-position solenoid valves consists of 3 pressure holding valves [(1), (2), (3)] and 3 pressure
reduction valves [(4), (5), (6)].

gHydraulic Circuitg

Master Cylinder and

Brake Booster

Brake Actuator

(1) (2) (3)

Pumps

(4) (5) Reservoirs (6)

LSP & BV

Front Left Front Right Rear Left Rear Right

271CH53
CH-84 CHASSIS-BRAKE

5. System Operation

ABS Operation

Based on the signals received from the 4 wheel speed sensors, the skid control ECU calculates each
wheel speed and deceleration, and checks wheel slipping condition. According to the slipping condition,
the ECU controls the pressure holding valve and pressure reduction valve in order to adjust the fluid
pressure of each wheel cylinder in the following 3 modes: pressure reduction, pressure holding, and
pressure increase modes.

Not Activated Normal Braking  

Activated Increase Mode Holding Mode Reduction Mode

Hydraulic
Circuit Port A
Pressure
Holding
Solenoid
Valve
To
Reservoir
and Pump
Pressure
Holding Valve Port BOFF (Open) ON (Close) ON (Close)
Pressure
(Port A) Reduction
Solenoid
Pressure Valve
To Wheel From Wheel
Cylinder Cylinder 169CH56
Reduction Valve OFF (Close)169CH54 OFF (Close)
169CH55 ON (Open)
(Port B)
Wheel Cylinder
Increase Hold Reduction
Pressure
 CHASSIS-BRAKE CH-85

6. Skid Control ECU

Initial Check

After the ignition switch is turned ON, and the vehicle attains an approximate speed of 6 km/h (4 mph)
or more only at first time, the skid control ECU performs the initial check.
The function of each solenoid valve and pump motor in the brake actuator are check in order.

Self-Diagnosis

 If the skid control ECU detects a malfunction in the ABS system, the ABS warning light that
corresponds to the function in which the malfunction has been detected indicates or lights up,
indicated in the table below, to alert the driver of the malfunction.

: Light ON : Light OFF

Item ABS Skid Control ECU

ABS Warning Light  

 At the same time, the DTCs (Diagnostic Trouble Codes) are stored in memory. The DTCs can be read
by connecting the SST (09843-18040) between the Tc and CG terminals of DLC3 and observing the
blinks of the ABS warning light (2-digit code), or by connecting an intelligent tester II (5-digit code).
 This system has a sensor signal check (test mode) function. This check function performs speed sensor
check. This function is activated by connecting an intelligent tester II.
 If the skid control ECU detects a malfunction during a sensor check, it stores the DTC in its memory.
This DTC can be read during a sensor signal check operation by connecting the Tc and CG terminals
of the DLC3 and observing the blinking of the ABS warning light, or on an intelligent tester II.
 For details concerning the above, see the Hilux Repair Manual.

Fail-Safe

If a malfunction occurs in the signal system of the ABS system, the skid control ECU disables the ABS
control.