Front Brake Pad, Brake Caliper & Brake Rotor: Overhaul

HINT:

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

1. REMOVE FRONT WHEEL 
2. DRAIN BRAKE FLUID 
   NOTE: Wash brake fluid off immediately if it adheres to any painted surface.
3. REMOVE FRONT DISC BRAKE CYLINDER SUB-ASSY 
   1. Remove the union bolt and gasket from the disc brake cylinder, then disconnect the flexible hose.

      HINT:

      Gasket has 2 types: 2-piece type and 1-piece type.

      Fig 1: Disconnecting Flexible Hose

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

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. REMOVE DISC BRAKE PAD KIT FRONT (PAD ONLY) 
   1. Remove the 2 brake pads with anti-squeal shims.
   2. Remove the anti-squeal shim No.1 and anti-squeal shim No.2 from each pad.
   3. Remove the indicator plate from inner pad.
5. REMOVE FRONT DISC BRAKE PAD SUPPORT PLATE 
   1. Remove the pad support plate (No.1) from the cylinder mounting.
6. REMOVE FRONT DISC BRAKE PAD SUPPORT PLATE 
   1. Remove the pad support plate (No.2) from the cylinder mounting.
7. REMOVE FRONT DISC BRAKE CYLINDER SLIDE PIN 
   1. Remove the 2 cylinder slide Dins from the cylinder mounting.
8. REMOVE FRONT DISC BRAKE CYLINDER MOUNTING LH 
   1. Remove the 2 bolts and cylinder mounting.
   Fig 3: Removing Bolts And Cylinder Mounting

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. REMOVE FRONT DISC BRAKE BUSH DUST BOOT 
   1. Place the cylinder mounting in a vise.
   2. Using a screwdriver and a hammer, remove the 2 bush dust boots from the cylinder mounting.
   Fig 4: Removing Bush Dust Boots From Cylinder Mounting

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. REMOVE CYLINDER BOOT 
    1. Using a screwdriver, remove the set ring and cylinder boot.
    Fig 5: Removing Set Ring And Cylinder Boot

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. REMOVE FRONT DISC BRAKE PISTON 
    1. Place a piece of shop rag or equivalent between the piston and the disc brake cylinder assy.
    2. Use compressed air to remove the piston from the disc brake cylinder assy.
    Fig 6: Removing Piston From Disc Brake Cylinder Assy

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    CAUTION: Do not place your fingers in front of the piston when using compressed air.
    NOTE: Do not spatter the brake fluid
12. REMOVE PISTON SEAL 
    1. Using a screwdriver, remove the piston seal from the disc brake cylinder assy.
    NOTE: Do not damage the inner cylinder and cylinder groove.
13. REMOVE FRONT DISC BRAKE BLEEDER PLUG 
14. INSPECT BRAKE CYLINDER AND PISTON 
    1. Check the cylinder bore and piston for rust or scoring. If necessary, replace the disc brake cylinder assy and piston.
15. 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.) 

    If the pad lining thickness is equal to the minimum thickness or less, replace the brake pad kit front.

    Fig 7: Measuring Pad Lining Thickness

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
16. INSPECT FRONT DISC BRAKE PAD SUPPORT PLATE 
    1. Make sure that both plates have sufficient rebound, have no deformation, cracks or wear, and that all rust and dirt are cleaned off.

       If necessary, replace the pad support plate (No.1).

17. INSPECT FRONT DISC BRAKE PAD SUPPORT PLATE 
    1. Make sure that both plates have sufficient rebound, have no deformation, cracks or wear, and that all rust and dirt are cleaned off.

    If necessary, replace the pad support plate (No.2).

18. INSPECT DISC THICKNESS 
    1. Using a micrometer, measure the disc thickness.

       Standard thickness: 25.0 mm (0.984 in.) 

       Minimum thickness: 23.0 mm (0.906 in.) 

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

    Fig 8: Measuring Disc Thickness

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
19. REMOVE FRONT DISC 
    1. Put matchmarks on the disc and the axle hub.
    2. Remove the front disc.
20. INSTALL FRONT DISC 
    1. Aligning the matchmarks, install the front disc.
    NOTE: When replacing the disc with a new one, select the installation position where the front disc has the minimum runout.
    Fig 9: Putting Matchmarks On Disc And Axle Hub

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
21. INSPECT DISC RUNOUT 
    1. Check the bearing play in the axial direction and check for the axle hub runout (see ON-VEHICLE INSPECTION ).
    2. Temporarily fasten the front disc together with the hub nuts.

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

    3. Using a dial indicator, 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.) 

    Fig 10: Measuring Disc Runout Away From Outer Edge Of Front Disc

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    If the runout exceeds the maximum value, change the installation positions of the disc and axle so that the runout will become minimal. If the runout exceeds the maximum even when the installation positions are changed, grind the disc. If the disc thickness is less than the minimum, replace the front disc.

22. TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG 
23. INSTALL PISTON SEAL 
    1. Apply lithium soap base glycol grease to a new piston seal.
    2. Install the piston seal to the disc brake cylinder assy.
24. INSTALL FRONT DISC BRAKE PISTON 
    1. Apply the lithium soap base glycol grease to the piston.
    2. Install the piston to the disc brake cylinder assy.
    NOTE: Do not screw the piston forcedly in the disc brake cylinder assy.
25. INSTALL CYLINDER BOOT 
    1. Apply the lithium soap base glycol grease to a new cylinder boot.
    2. Install the cylinder boot to the disc brake cylinder assy.

       HINT:

       Install the boot securely to the grooves of the cylinder and piston.

    3. Using a screwdriver, install the set ring.
    NOTE: Do not damage the cylinder boot.
    Fig 11: Installing Cylinder Boot To Disc Brake Cylinder Assy

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
26. INSTALL FRONT DISC BRAKE BUSH DUST BOOT 
    1. Place the cylinder mounting in a vise.
    2. Apply the lithium soap base glycol grease to seal surface of 2 new bush dust boots.
    3. Using a socket wrench (19 mm) and a hammer, drive the 2 bush dust boots in the cylinder mounting.
    Fig 12: Driving Bush Dust Boots In Cylinder Mounting

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
27. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING LH 
    1. Install the cylinder mounting with the 2 bolts.

       Torque: 107 N.m (1,089 kgf.cm, 79 ft.lbf) 

28. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN 
    1. Apply the lithium soap base glycol grease to the sliding part of the 2 cylinder slide pins.
    2. Install the 2 cylinder slide pins to the cylinder mounting.
29. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE 
    1. Install the pad support plate (No.1) to the cylinder mounting.
30. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE 
    1. Install the pad support plate (No.2) to the cylinder mounting.
31. INSTALL DISC BRAKE PAD KIT FRONT (PAD ONLY) 
    NOTE: When replacing the brake pads, the anti-squeal shims must be replaced together with the brake pads.
    1. Apply disc brake grease to each anti-squeal shim No.1.
    2. Install the anti-squeal shims on each pad.
    3. Install the indicator plate to the upper side of the inner pad.
    4. Install the brake pads to the cylinder mounting.
    NOTE: Install the brake pads in correct position and direction.
    Fig 13: Installing Disc Brake Pad Kit Front

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
32. INSTALL FRONT DISC BRAKE CYLINDER SUB-ASSY 
    1. Install the disc brake cylinder with the 2 bolts.

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

       Fig 14: Installing Disc Brake Cylinder With Bolts

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install a new gasket and flexible hose with the union bolt.

       Torque: 29 N.m (296 kgf.cm, 21 ft.lbf) 

    NOTE: Install the flexible hose lock securely in the lock hole in the disc brake cylinder.

    HINT:

    Gasket has 2 types: 2-piece type and 1-piece type.

    Fig 15: Installing Gasket And Flexible Hose With Union Bolt

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
33. FILL RESERVOIR WITH BRAKE FLUID (see  BRAKE FLUID  ) 
34. BLEED MASTER CYLINDER (see  BRAKE FLUID  ) 

    SST 09023-00101

35. BLEED BRAKE LINE (see  BRAKE FLUID  ) 
36. CHECK FLUID LEVEL IN RESERVOIR (see  BRAKE FLUID  ) 
37. CHECK FOR BRAKE FLUID LEAKAGE 
38. INSTALL FRONT WHEEL 

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