Rear 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 REAR WHEEL
DRAIN BRAKE FLUID
NOTE: Wash off the brake fluid immediately if it comes into contact with a painted surface.
DISCONNECT REAR LH FLEXIBLE HOSE
1. Remove the union bolt and gasket from the disc brake cylinder, then disconnect the flexible hose from the disc brake cylinder assy rear.
HINT:

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

Fig 1: Removing Union Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DISC BRAKE CYLINDER ASSY REAR LH
1. Remove the 2 cylinder slide pins from disc brake cylinder assy rear.
2. Remove the disc brake cylinder assy rear from rear disc brake cylinder mounting.
  
  Fig 2: Removing Disc Brake Cylinder Assy Rear From Rear Disc Brake Cylinder Mounting
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DISC BRAKE PAD KIT REAR (PAD ONLY)
1. Remove the 2 brake pads with anti-squeal shims from rear disc brake cylinder mounting.
REMOVE REAR DISC BRAKE ANTI-SQUEAL SHIM
1. Remove the 2 anti-squeal shims from each disc brake pads.
REMOVE REAR DISC BRAKE PAD WEAR INDICATOR PLATE
1. Remove the pad wear indicator plate from the inner side disc brake pad.
REMOVE REAR DISC BRAKE PAD SUPPORT PLATE
1. Remove the 4 pad support plates from the rear disc brake cylinder mounting.
REMOVE REAR DISC BRAKE CYLINDER MOUNTING LH
1. Remove the 2 bolts and rear brake cylinder mounting.
  
  Fig 3: Removing Bolts & Rear Brake Cylinder Mounting
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DISC BRAKE CYLINDER SLIDE BUSH
1. Remove the 2 cylinder slide bushes from the rear disc brake cylinder mounting.
2. Remove the cylinder hole plug from the rear disc brake cylinder mounting.
REMOVE CYLINDER BOOT
1. Using a screwdriver, remove the cylinder boot from disc brake cylinder assy rear.
  
  Fig 4: Removing Cylinder Boot From Disc Brake Cylinder Assy Rear Using Screwdriver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DISC BRAKE PISTON
1. Place a of cloth or equivalent between the piston and the disc brake cylinder assy rear.
2. Use compressed air to remove the piston from the disc brake cylinder assy rear.
  CAUTION: Do not place your fingers in front of the piston when using compressed air.
  
  NOTE: Do not spatter the brake fluid.
REMOVE PISTON SEAL
1. Using a screwdriver, remove the piston seal from the disc brake cylinder assy rear.
  
  Fig 5: Using Compressed Air To Remove Piston From Disc Brake Cylinder Assy Rear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Fig 6: Removing Piston Seal From Disc Brake Cylinder Assy Rear Using Screwdriver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DISC BRAKE BLEEDER PLUG
1. Remove the bleeder plug cap and bleeder plug from disc brake cylinder assy rear.
INSPECT BRAKE CYLINDER AND PISTON
1. Check the cylinder bore and piston for rust or scarring.
INSPECT PAD LINING THICKNESS
1. Using a ruler, measure the pad lining thickness.
  Standard thickness: 10.0 mm (0.394 in.)
  
  Minimum thickness: 1.0 mm (0.039 in.)
  
  Fig 7: Measuring Pad Lining Thickness Using Ruler
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT REAR DISC BRAKE PAD SUPPORT PLATE
1. Inspect the 4 pad support plates. Make sure the plates have sufficient rebound check for deformation, cracks or wear, rust, dirt or foreign particles.
INSPECT DISC THICKNESS
1. Using a micrometer, measure the disc thickness.
  Standard thickness: 18.0 mm (0.709 in.)
  
  Minimum thickness: 16.0 mm (0.630 in.)
  
  Fig 8: Measuring Disc Thickness Using Micrometer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DISC
1. Make matchmarks on the rear disc and the axle hub.
2. Remove the rear disc.
INSTALL REAR DISC
1. Align the matchmarks and install the rear disc.
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: 0.20 mm (0.0079 in.)
  
  Fig 9: Measuring Disc Runout Using Dial Indicator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 a "On-car" brake lathe.
TEMPORARILY TIGHTEN REAR DISC BRAKE BLEEDER PLUG
1. Temporarily tighten the bleeder plug to the disc brake cylinder assy rear.
2. Install the bleeder plug cap on the bleeder plug.
INSTALL PISTON SEAL
1. Apply the lithium soap base glycol grease to a new piston seal.
2. Install the piston seal on the disc brake cylinder assy rear.
INSTALL REAR DISC BRAKE PISTON
1. Apply the lithium soap base glycol grease to a disc brake piston.
2. Install the disc brake piston on the disc brake cylinder assy rear.
  NOTE: Do not screw the disc brake piston forcedly in the disc brake cylinder assy rear.
INSTALL CYLINDER BOOT
1. Apply the lithium soap base glycol grease to a new cylinder boot.
2. Install the cylinder boot on the disc brake cylinder
HINT:

Install the cylinder boot securely on the grease of the disc brake cylinder assy and piston.
INSTALL REAR DISC BRAKE CYLINDER SLIDE BUSH
1. Apply the lithium soap base glycol grease to a new cylinder hole plug and 2 new cylinder slide bushes.
2. Install the cylinder hole plug and 2 cylinder slide bush to the rear disc brake cylinder mounting.
INSTALL REAR DISC BRAKE CYLINDER MOUNTING LH
1. Install the rear disc brake cylinder mounting with 2 bolts.
  Torque: 105 N.m (1,071 kgf.cm, 77 ft.lbf)
  
  Fig 10: Installing Rear Disc Brake Cylinder Mounting With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR DISC BRAKE PAD SUPPORT PLATE
1. Install the 4 pad support plates on the rear disc brake cylinder mounting.
INSTALL REAR DISC BRAKE PAD WEAR INDICATOR PLATE
1. Install the pad wear indicator plate on the inner side disc brake pad.
HINT:

Install the pad wear indicator facing downward.
INSTALL REAR DISC BRAKE ANTI-SQUEAL SHIM
NOTE: If necessary, replace the anti-squeal shim kit when replacing the brake pad.
1. Install the 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 rear disc.
INSTALL DISC BRAKE PAD KIT REAR (PAD ONLY)
1. Install the 2 disc brake pads with anti-squeal shim to the disc brake cylinder assy.
INSTALL DISC BRAKE CYLINDER ASSY REAR LH
1. Apply the lithium soap base glycol grease to the sliding part of 2 cylinder slide pins.
2. Install the disc brake cylinder assy rear with 2 cylinder slide pins.
  Torque: 88 N.m (897 kgf.cm, 65 ft.lbf)
  
  Fig 11: Installing Disc Brake Cylinder Assy Rear With Cylinder Slide Pins
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT REAR LH FLEXIBLE HOSE
1. Connect the flexible hose with union bolt and new gasket to the disc brake cylinder assy rear.
  Torque: 31 N.m (316 kgf.cm, 23 ft.lbf)
  
  Fig 12: Installing Union Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
FILL RESERVOIR WITH BRAKE FLUID
BLEED BRAKE LINE (1GR-FE See BLEEDING )
CHECK FLUID LEVEL IN RESERVOIR
CHECK BRAKE FLUID LEAKAGE
INSTALL REAR WHEEL
Torque: 110 N.m (1,122 kgf.cm, 81 ft.lbf)