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Front Brake Pad, Brake Caliper & Brake Rotor: Overhaul

HINT:

Overhaul the RH side using the same procedures as those for the LH side.

  1. REMOVE FRONT WHEEL 
  2. DRAIN BRAKE FLUID 
    NOTE: Wash the brake fluid off immediately if it adheres to any painted surfaces.
  3. DISCONNECT FRONT FLEXIBLE HOSE 
    1. Remove the union bolt and the gasket from the disc brake cylinder sub-assy, then disconnect the flexible hose.
  4. REMOVE DISC BRAKE CYLINDER ASSY LH 
    1. Hold the front disc brake cylinder slide pin, slide pin (No.2) and remove the 2 bolts.
      Fig 1: Removing Disc Brake Cylinder Assy LH
      G03006706Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE DISC BRAKE PAD KIT FRONT (PAD ONLY) 
    1. Remove the 2 brake pads w/anti squeal shim from the cylinder mounting LH.
  6. REMOVE ANTI SQUEAL SHIM KIT FRONT 
    1. Remove the 2 anti squeal shims from each pads.
    2. Using a screwdriver, remove the pad wear indicator from the inner pad.
  7. REMOVE FRONT DISC BRAKE PAD SUPPORT PLATE 
    1. Remove the front disc brake pad support plate (No.1) and the front disc brake pad support plate (No.2) from the front disc brake cylinder mounting LH.
  8. REMOVE FRONT DISC BRAKE CYLINDER SLIDE PIN 
    1. Remove the front disc brake cylinder slide pin from the front disc brake cylinder mounting LH
  9. REMOVE FRONT DISC BRAKE CYLINDER SLIDE PIN NO. 2 
    1. Remove the front disc brake cylinder slide pin (No.2) from the front disc brake cylinder mounting LH.
      Fig 2: Removing Front Disc Brake Cylinder Slide Pin No.2
      G03006707Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE FRONT DISC BRAKE CYLINDER SLIDE BUSH 
    1. Remove the front disc brake cylinder slide bush from the front disc brake cylinder slide pin No.2.
      NOTE: Do not damage the front disc brake cylinder slide pin No.2.
      Fig 3: Removing Front Disc Brake Cylinder Slide Bush
      G03006708Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE FRONT DISC BRAKE BUSH DUST BOOT 
    1. Remove the 2 front disc brake cylinder bush dust boots from the front disc brake cylinder mounting LH.
      Fig 4: Removing Front Disc Brake Bush Dust Boot
      G03006709Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE FRONT DISC BRAKE CYLINDER MOUNTING LH 
    1. Remove the 2 bolts and the front disc brake cylinder mounting LH.
      Fig 5: Removing Front Disc Brake Cylinder Mounting LH
      G03006710Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE CYLINDER BOOT 
    1. Using a screwdriver, remove the cylinder boot.
      NOTE: Do not damage the inner cylinder and cylinder groove.
      Fig 6: Removing Cylinder Boot
      G03006711Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE FRONT DISC BRAKE PISTON 
    1. Place a shop rug between the brake piston and the disc brake cylinder sub-assy.
    2. Use compressed air to remove the brake piston from the disc brake cylinder sub-assy.
      CAUTION: Do not place your fingers in front of the brake piston when using compressed air.
      NOTE: Do not spatter the brake fluid.
      3. Fig 7: Removing Front Disc Brake Piston
      G03006712Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE PISTON SEAL 
    1. Using a screwdriver, remove the piston seal.
      NOTE: Do not damage the inner cylinder and cylinder groove.
      Fig 8: Removing Piston Seal
      G03006713Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE FRONT DISC BRAKE BLEEDER PLUG CAP 
    1. Remove the bleeder plug cap to the front disc brake bleeder plug.
  17. REMOVE FRONT DISC BRAKE BLEEDER PLUG 
    1. Remove the front disc brake bleeder plug from the disc brake cylinder sub-assy.
  18. INSPECT BRAKE CYLINDER AND PISTON 
    1. Check the brake cylinder bore and the brake piston for rust or scoring.
  19. INSPECT PAD LINING THICKNESS 
    1. Using a ruler, measure the pad lining thickness.

      Standard thickness: 11.0 mm (0.433 in.) 

      Minimum thickness: 1.0 mm (0.039 in.) 

      Fig 9: Inspecting Pad Lining Thickness
      G03006714Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSPECT FRONT DISC BRAKE PAD SUPPORT PLATE 
    1. Inspect the front disc brake pad support plate (No.1) and the front disc brake pad support plate (No.2). Make sure that it has sufficient rebound, no deformation cracks or wear, and all rust, dirt are cleaned off.
  21. INSPECT DISC THICKNESS 
    1. Using a micrometer, measure the disc thickness.

      Standard thickness: 28.0 mm (1.102 in.) 

      Minimum thickness: 26.0 mm (1.024 in.) 

      Fig 10: Inspecting Disc Thickness
      G03006715Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE FRONT DISC 
    1. Put matchmarks on the front disc and the axle hub.
    2. Remove the front disc.
  23. INSTALL FRONT DISC 
    1. Align the matchmarks, install the front disc.

      HINT:

      When replacing the disc with a new one, select the installation position where the front disc has the minimum runout.

      Fig 11: Aligning Matchmarks To Install Front Disc
      G03006716Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. INSPECT DISC RUNOUT 
    1. Temporarily install the front disc with hub nuts.

      Torque: 103 N.m (1,050 kgf.cm, 76 ft.lbf) 

    2. Using a dial gauge, measure the disc runout 10 mm (0.39 in.) away from the outer edge of the front disc.

      Maximum disc runout: 0.05 mm (0.0020 in.) 

    3. If the disc runout is greater than the maximum value, check the bearing play in the axial direction and check the axle hub runout (See ON-VEHICLE INSPECTION ). If the bearing play and axle hub runout are normal, adjust the disc runout or grind it on a "On-car" brake lathe.
      Fig 12: Inspecting Disc Runout
      G03006717Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG 
    1. Temporarily tighten the front disc brake bleeder plug to the disc brake cylinder sub-assy.
  26. INSTALL FRONT DISC BRAKE BLEEDER PLUG CAP 
    1. Install the bleeder plug cap to the front disc brake bleeder plug.
  27. INSTALL PISTON SEAL 
    1. Apply the lithium soap base glycol grease to a new piston seal.
    2. Install the piston seal to the disc brake cylinder sub-assy.
  28. INSTALL FRONT DISC BRAKE PISTON 
    1. Apply lithium soap base glycol grease to the front disc brake piston and a new cylinder boot.
    2. Install the cylinder boot to the front disc brake piston.
    3. Install the piston to the front disc brake cylinder sub-assy.
      NOTE: Do not install the piston forcibly in the disc brake cylinder.
      4. Fig 13: Installing Front Disc Brake Piston
      G03006718Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. INSTALL CYLINDER BOOT 
    1. Install the cylinder boot to the front disc brake cylinder.
      Fig 14: Installing Cylinder Boot
      G03006719Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Install the boot securely to the grooves of the cylinder and piston.
      • Do not damage the cylinder boot.
  30. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING LH 
    1. Install the front disc brake cylinder mounting LH with the 2 bolts.

      Torque: 104 N.m (1,061 kgf.cm, 77 ft.lbf) 

      Fig 15: Installing Front Disc Brake Cylinder Mounting LH
      G03006720Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. INSTALL FRONT DISC BRAKE BUSH DUST BOOT 
    1. Apply lithium soap base glycol grease to the sealing surface of 2 new front disc brake bush dust boots.
    2. Install the 2 front disc brake bush dust boots to the front disc brake cylinder mounting LH.
      Fig 16: Installing Front Disc Brake Bush Dust Boot
      G03006721Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. INSTALL FRONT DISC BRAKE CYLINDER SLIDE BUSH 
    1. Apply lithium soap base glycol grease to the a new front disc brake cylinder slide bush.
    2. Install the front disc brake cylinder slide bush to the front disc brake cylinder slide pin No.2.
      Fig 17: Installing Front Disc Brake Cylinder Slide Bush
      G03006722Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN NO. 2 
    1. Apply the lithium soap base glycol grease to the sliding part and the seal surface of the slide pin No.2.
    2. Install the front disc brake cylinder slide pin No.2 to the bottom side of the cylinder mounting LH.
      3. Fig 18: Installing Front Disc Brake Cylinder Slide Pin No 2
      G03006723Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN 
    1. Apply the lithium soap base glycol grease to the sliding part and the seal surface of the slide pin.
    2. Install the front disc brake cylinder slide pin.
  35. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE 
    1. Install the front disc brake pad support plate (No.1) and the front disc brake pad support plate (No.2) to the front disc brake cylinder mounting LH.
  36. INSTALL ANTI SQUEAL SHIM KIT FRONT 
    1. Apply disc brake grease to the anti squeal shims and install them to each pad.
      NOTE:
      • When replacing worn pads, the anti squeal shims must be replaced together with the pads.
      • Install the shims correctly of which positions and directions.
      2. Fig 19: Installing Anti Squeal Shim Kit Front
      G03006724Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the pad wear indicator to the inner pad.
      NOTE: Install the pad wear indicator correctly of which positions and directions.
  37. INSTALL DISC BRAKE PAD KIT FRONT (PAD ONLY) 
    1. Install the 2 brake pads w/anti squeal shim to the disc brake cylinder mounting LH.
      NOTE: There should be no oil or grease on the friction surface of the pads and the disc.
  38. INSTALL DISC BRAKE CYLINDER ASSY LH 
    1. Install the disc brake cylinder assy LH with the 2 bolts.

      Torque: 34 N.m (350 kgf.cm, 25 ft.lbf) 

      2. Fig 20: Installing Disc Brake Cylinder Assy LH With Bolts
      G03006725Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. CONNECT FRONT FLEXIBLE HOSE 
    1. Connect the flexible hose with the union bolt and a new gasket.

      Torque: 29 N.m (300 kgf.cm, 21 ft.lbf) 

      NOTE: Install the flexible hose lock securely in the lock hole in the disc brake cylinder sub-assy.
  40. FILL RESERVOIR WITH BRAKE FLUID (See  BRAKE FLUID  ) 
  41. BLEED MASTER CYLINDER (See  BRAKE FLUID  ) 

    SST 09023-00101

  42. BLEED BRAKE LINE (See  BRAKE FLUID  ) 
  43. CHECK FLUID LEVEL IN RESERVOIR (See  BRAKE FLUID  ) 
  44. CHECK BRAKE FLUID LEAKAGE 
  45. INSTALL FRONT WHEEL 

    Torque: 103 N.m (1,050 kgf.cm, 76 ft.lbf) 

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