Front Brake Pad, Brake Caliper & Brake Rotor: Installation

HINT:

• Use the same procedures for the LH side and RH side.
• The procedures listed below are for the LH side.

1. INSTALL FRONT DISC 
   1. Align the matchmarks and install the disc.

      HINT:

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

      Fig 1: Identifying Matchmarks

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. CHECK DISC RUNOUT 
   1. Check the bearing play in the axle direction and check the axle hub runout (see ON-VEHICLE INSPECTION ).
   2. Temporarily install the disc to the hub with the 2 hub nuts.
   3. Using a dial indicator, measure the disc runout 10 mm (0.3 in.) away from the outer edge of the disc.

      Minimum disc runout: 

      0.05 mm (0.0020 in.) 

      If the runout is greater than the maximum, change the installation position of the disc and axle so that the runout will become minimal.

      Fig 2: Checking Disc Runout

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      If the runout is greater than the maximum even when the installation positions are changed, grind the disc.

      If the disc thickness is less than the minimum, replace the disc.

   4. Remove the 2 hub nuts.
3. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING LH 
   1. Install the cylinder mounting with the 2 bolts.

      Torque: 107 N*m (1,090 kgf*cm, 79 ft.*lbf) 

4. INSTALL FRONT DISC BRAKE BUSH DUST BOOT 
   1. Apply lithium soap base glycol grease to the seal surface of 2 new dust boots.
   2. Install the dust boots to the cylinder mounting.
      Fig 3: Identifying Front Disc Brake Bush Dust Boot

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN 
   1. Apply lithium soap base glycol grease to the sliding part and the seal surface of the 2 cylinder slide pins.
   2. Install the 2 cylinder slide pins to the cylinder mounting.
   Fig 4: Installing Front Disc Brake Cylinder Slide Pin
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE 
   1. Install the support plate (No. 1 and No. 2) to the cylinder mounting.
7. INSTALL FRONT ANTI SQUEAL SHIM 
   1. Apply disc brake grease to the both side of the shims (inner).
   2. Install the shims (inner and outer) to each pad.
      NOTE:

      • When replacing worn pads, the shims must be replaced together with the pads.
      • Install the shims in the correct positions and direction.
   3. Install the pad wear indicator plate to the pad (inner).
      Fig 5: Identifying Front Anti Squeal Shim

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Install the pad wear indicator plate in the correct position and direction.
8. INSTALL FRONT DISC BRAKE PAD 
   1. Install the 2 pads to the cylinder mounting.
      NOTE: There should be no oil or grease on the friction surface of the pads and disc.
9. INSTALL FRONT DISC BRAKE CYLINDER ASSEMBLY LH 
   1. Install the brake cylinder with the 2 bolts.

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

   2. Connect the flexible hose with the union bolt and a new gasket.

      Torque: 30 N*m (310 kgf*cm, 22 ft.*lbf) 

      NOTE: Connect the flexible hose lock securely in the lock hole in the brake cylinder.
10. FILL RESERVOIR WITH BRAKE FLUID (See  BRAKE FLUID  )
11. BLEED AIR FROM BRAKE MASTER CYLINDER (See  BRAKE FLUID  )
12. BLEED AIR FROM BRAKE LINE (See  BLEEDING  )
13. CHECK BRAKE FLUID LEVEL IN RESERVOIR (See  BLEEDING  )
14. CHECK FOR BRAKE FLUID LEAKAGE 
15. INSTALL FRONT WHEEL LH 

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