Front Brake Pad, Brake Caliper & Brake Rotor: Overhaul

HINT:

Overhaul procedure of the RH side is the same as that of LH side.

1. REMOVE FRONT WHEEL 
2. DRAIN BRAKE FLUID 
   NOTE: Wash off the brake fluid immediately if it comes into contact with a painted surface.
3. REMOVE FRONT DISC BRAKE ANTI-RATTLE W/ HOLE PIN 
   1. Remove the 2 pin hole clips, then remove the 2 anti-rattle with hole pins from the disc brake cylinder assy.
   2. Remove the anti-rattle spring from the disc brake pad.
      Fig 1: Removing Pin Hole Clips

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. REMOVE DISC BRAKE PAD KIT FRONT (PAD ONLY) 
   1. Remove the 2 disc brake pads with anti-squeal shim from the disc brake cylinder assy.
5. REMOVE ANTI SQUEAL SHIM KIT FRONT 
   1. Remove the 2 anti-squeal shims from each of the disc brake pads.
6. REMOVE DISC BRAKE CYLINDER ASSY LH 
   1. Using SST, disconnect the brake tube from the disc brake cylinder assy.

      SST 09023-00101

      HINT:

      Use a container to catch brake fluid as it drains out.

      Fig 2: Disconnecting Brake Tube From Disc Brake Cylinder Assy Using SST

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Remove the 2 bolts and remove the disc brake cylinder assy.
      Fig 3: Removing Disc Brake Cylinder Assy With Bolts

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. REMOVE CYLINDER BOOT 
   1. Using a screwdriver, remove the 4 cylinder boots from the caliper.
      Fig 4: Removing Cylinder Boots From Caliper Using Screwdriver

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. REMOVE FRONT DISC BRAKE PISTON 
   1. Prepare the wooden plate to hold the pistons.
      Fig 5: Identifying Wooden Plate Dimension

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Place the plate between the pistons and insert a pad at one side.
   3. Use compressed air to remove the pistons alternately from the cylinder.
   CAUTION: Do not place your fingers in front of the piston when using compressed air.
   Fig 6: Removing Pistons Alternately From Cylinder Using Compressed Air

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. REMOVE PISTON SEAL 
   1. Using a screwdriver, remove the 4 piston seals from the cylinder.
      Fig 7: Removing Piston Seals From Cylinder Using Screwdriver

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. REMOVE FRONT DISC BRAKE BLEEDER PLUG 
    1. Remove the breeder plug cap and breeder plug from the disc brake cylinder assy.
11. INSPECT BRAKE CYLINDER AND PISTON 
    1. Check the cylinder bore and piston for rust or scoring.
12. INSPECT PAD LINING THICKNESS 
    1. Using a ruler, measure the pad lining thickness.

       Standard thickness: 11.5 mm (0.453 in.) 

       Minimum thickness: 1.0 mm (0.039 in.) 

       Fig 8: Measuring Pad Lining Thickness Using Ruler

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
13. 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 9: Measuring Disc Thickness Using Micrometer

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
14. REMOVE FRONT DISC 
    1. Make matchmarks on the disc and the axle hub.
    2. Remove the front disc.
15. INSTALL FRONT DISC 
    1. Aligning the matchmarks on the rear disc and axle hub, install the front disc.

       HINT:

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

16. INSPECT DISC RUNOUT 
    1. Temporarily fasten the disc with hub nuts.

       Torque: 112 N.m (1,142 kgf.cm, 83 ft.lbf) 

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

       Maximum disc runout: 0.05 mm (0.0020 in.) 

    3. If the disc runout is the maximum value or greater, 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 the "On-car" brake lathe.
       Fig 10: Measuring Disc Runout Using Dial Indicator

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
17. TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG 
    1. Temporarily tighten the bleeder plug to the disc brake cylinder assy.
    2. Install the breeder plug cap to the breeder plug.
18. INSTALL PISTON SEAL 
    1. Apply the lithium soap base glycol grease to the 4 new piston seals.
    2. Install the 4 piston seals to the disc brake cylinder assy.
19. INSTALL FRONT DISC BRAKE PISTON 
    1. Apply the lithium soap base glycol grease to the 4 disc brake pistons.
    2. Install the 4 disc brake pistons on the disc brake cylinder assy.
    NOTE: Do not screw the disc brake piston forcedly in the disc brake cylinder assy.
20. INSTALL CYLINDER BOOT 
    1. Apply the lithium soap base glycol grease to the 4 new cylinder boots.
    2. Install the 4 cylinder boots on the disc brake cylinder assy.

    HINT:

    Install the cylinder boot securely on the grooves of the disc brake cylinder and piston.

21. INSTALL DISC BRAKE CYLINDER ASSY LH 
    1. Install the disc brake cylinder assy with 2 bolts.

       Torque: 123 N.m (1,254 kgf.cm, 91 ft.lbf) 

       Fig 11: Installing Disk Brake Cylinder Assy With Bolts

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, connect the brake tube to the disc brake cylinder assy.

       SST 09023-00101

       Torque: 15.0 N.m (153 kgf.cm, 11 ft.lbf) 

       Fig 12: Connecting Brake Tube To Disc Brake Cylinder Assy Using SST

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
22. INSTALL ANTI SQUEAL SHIM KIT FRONT 
    NOTE: If necessary, replace the anti-squeal shim kit when replacing the brake pad.
    1. Install the 2 anti-squeal shims on each brake pad.
    NOTE: There should be no oil or grease on the friction surfaces of the brake pads and the front disc.
23. INSTALL DISC BRAKE PAD KIT FRONT (PAD ONLY) 
    1. Install the 2 disc brake pads with anti-squeal shim to the disc brake cylinder assy.
24. INSTALL FRONT DISC BRAKE ANTI-RATTLE W/ HOLE PIN 
    1. Install the 2 anti-rattle with hole pins and anti-rattle spring to the disc brake cylinder.

       HINT:

       The anti-rattle spring is installed to the bottom side of anti-rattle with hole pin.

    2. Install the 2 pin hole clips to the anti-rattle with hole pin.
    NOTE: When installing the pin hole clip, be sure to install the pin hole clip with the handle facing to the vehicle center.
    Fig 13: Installing Pin Hole Clips

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
25. BLEED BRAKE LINE (See  BLEEDING   ) 
26. CHECK FLUID LEVEL IN RESERVOIR 
27. CHECK BRAKE FLUID LEAKAGE 
28. INSTALL FRONT WHEEL 

    Torque: 112 N.m (1,142 kgf.cm, 83 ft.lbf)