Front Brake Pad, Brake Caliper & Brake Rotor: Overhaul

WARNING: This page is about a different car, the 2006 Toyota 4Runner. However, it is still accessible from the selected car via links, so may be relevant.

HINT:

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

REMOVE FRONT WHEEL
DRAIN BRAKE FLUID
NOTE: Wash off the brake fluid immediately if it comes into contact with a painted surface.
REMOVE FRONT DISC BRAKE ANTI-RATTLE W/HOLE PIN
1. Remove the 2 pin hole clips, then remove the 2 anti-rattle w/ hole pins from 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
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.
REMOVE ANTI SQUEAL SHIM KIT FRONT
1. Remove the 2 anti-squeal shims from each of the disc brake pads.
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: Removing Disc Brake Cylinder Assy LH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2 bolts and remove the disc brake cylinder assy.
  
  Fig 3: Removing Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CYLINDER BOOT
1. Using a screwdriver, remove the 4 cylinder boots from the caliper.
  
  Fig 4: Removing Cylinder Boots Using Screwdriver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DISC BRAKE PISTON
1. Prepare the wooden plate to hold the pistons.
  
  Fig 5: Preparing Wooden Plate To Hold Pistons
  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: Using Compressed Air To Remove Pistons Alternately From Cylinder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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
REMOVE FRONT DISC BRAKE BLEEDER PLUG
1. Remove the breeder plug cap and breeder plug from the disc brake cylinder assy.
INSPECT BRAKE CYLINDER AND PISTON
1. Check the cylinder bore and piston for rust or scoring.
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
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
REMOVE FRONT DISC
1. Make matchmarks on the disc and the axle hub.
2. Remove the front disc.
INSTALL FRONT DISC
1. Aligning the matchmarks, install the front disc.
HINT:

When replacing the disc with a new one, select the installation position where the disc has the minimum runout.
INSPECT DISC RUNOUT
1. Temporarily fasten the disc with hub nuts.
  Torque: 110 N.m (1,122 kgf.cm, 81 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 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 a "On-car" brake lathe.
  
  Fig 10: Measuring Disc Runout Using Dial Indicator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
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.
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.
INSTALL CYLINDER BOOT
1. Apply the lithium soap grease 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.
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 Disc Brake Cylinder Assy Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, connect the brake tube to the disc brake cylinder assy.
  SST 09023-00101
  
  Torque: 15.2 N.m (155 kgf.cm, 11 ft.lbf)
  
  Fig 12: Connecting Brake Tube To Disc Brake Cylinder Assy Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL ANTI-SQUEAL SHIM KIT FRONT
NOTE: If necessary, replace the anti-squeal shim kit when replacing the brake pad.
1. Install the anti-squeal shims on each brake pads.
  NOTE: There should be no oil or grease on the friction surfaces of the brake pads and the front disc.
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.
INSTALL FRONT DISC BRAKE ANTI-RATTLE W/HOLE PIN
1. Install the 2 anti-rattle w/ hole pins and anti-rattle spring to the disc brake cylinder.
  HINT:
  
  Anti-rattle spring is installed with bottom side of anti-rattle w/hole pin.
2. Install the 2 new pin hole clips to the anti-rattle w/ 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 Front Disc Brake Anti-Rattle With Hole Pins & Anti-Rattle Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
FILL RESERVOIR WITH BRAKE FLUID
BLEED BRAKE LINE (See BLEEDING )
CHECK FLUID LEVEL IN RESERVOIR
CHECK BRAKE FLUID LEAKAGE
INSTALL FRONT WHEEL
Torque: 110 N.m (1,122 kgf.cm, 81 ft.lbf)