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Front Brake Pad, Brake Caliper & Brake Rotor: Reassembly

  1. INSTALL FRONT DISC 
    1. Aligning the matchmarks, install the front disc.

      HINT:

      Select the installation position where the disc has the minimum runout.

      Fig 1: Installing Front Disc Aligning Matchmarks
      G05195069Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSPECT DISC RUNOUT 
    1. Temporarily fasten the disc with hub nuts.

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

      Fig 2: Measuring Disc Runout
      G05195068Courtesy 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.
  3. TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG 
    1. Temporarily tighten the bleeder plug, and install bleeder plug cap to the disc brake cylinder.
  4. INSTALL PISTON SEAL 
    1. Apply the lithium soap base glycol grease on a new piston seal.
    2. Install the piston seal to the disc brake cylinder.
  5. INSTALL FRONT DISC BRAKE PISTON 
    1. Apply the lithium soap base glycol grease on the piston.
    2. Install the piston to the disc brake cylinder.
    NOTE: Do not screw the piston forcedly in the disc brake cylinder.
  6. INSTALL CYLINDER BOOT 
    1. Apply the lithium soap base glycol grease to a new cylinder boot. Install the cylinder boot to the disc brake cylinder.

      HINT:

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

    2. Using a screwdriver, install the set ring.
    NOTE: Do not damage the cylinder boot.
    Fig 3: Identifying Cylinder Boot
    G05195071Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL FRONT DISC BRAKE BUSH DUST BOOT 
    1. Place front disc brake cylinder mounting in 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 hammer, drive the 2 bush dust boots to the disc brake cylinder mounting.
      Fig 4: Driving Bush Dust Boots
      G05001707Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING LH 
    1. Install the disc brake cylinder mounting LH with the 2 bolts.

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

  9. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN 
    1. Apply the 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 disc brake cylinder mounting.
  10. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE 
    1. Install the 2 front disc brake pad support plates to the cylinder mounting.
  11. 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 anti-squeal shims on each pad.
    3. Install the pad wear 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 5: Identifying Disc Brake Pad Kit
    G05195073Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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