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Front Brake Pad, Brake Caliper & Brake Rotor: Reassembly

  1. INSTALL FRONT DISC 
    1. Align the matchmarks and 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.
  2. INSPECT DISC RUNOUT 
    1. Temporarily install the front disc with hub nuts.

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

      Fig 1: Aligning Matchmarks And Installing Front Disc
      G05202918Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. 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.) 

    3. If the disc runout is greater than the maximum value, check the bearing play in the axial direction and check the axle hub runout (See REMOVAL ). If the bearing looseness and axle hub runout are normal, adjust the disc to find the position where the disc has the minimum runout. When the disc is still unadjusted, grind it on an "On-car" brake lathe. In case the disc is too thin and ungrindable, try with a new disc.
      Fig 2: Measuring Disc Runout
      G05241808Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG 
    1. Temporarily tighten the front disc brake bleeder plug to the disc brake cylinder sub-assembly.
  4. INSTALL FRONT DISC BRAKE BLEEDER PLUG CAP 
    1. Install the bleeder plug cap to the front disc brake bleeder plug.
  5. 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 assembly.
  6. INSTALL FRONT DISC BRAKE PISTON 
    1. Apply lithium soap base glycol grease to the piston and a new cylinder boot.
    2. Install the cylinder boot to the piston.
      NOTE: Do not install the piston forcibly in the cylinder assembly.
      Fig 3: Installing Cylinder Boot To Piston
      G05202921Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL CYLINDER BOOT 
    1. Install the cylinder boot to the disc brake cylinder assembly.
      NOTE: Install the boot securely to the grooves of the cylinder and piston.
      Fig 4: Installing Cylinder Boot
      G05202922Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING 
    1. Install the cylinder mounting with the 2 bolts.

      Torque: 104 N*m (1,060 kgf*cm, 78 ft.*lbf) 

      Fig 5: Installing Front Disc Brake Cylinder Mounting
      G05202914Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL FRONT DISC BRAKE BUSHING DUST BOOT 
    1. Apply lithium soap base glycol grease to the seal surface of 2 new bushing dust boots.
    2. Install the 2 bushing dust boots to the front disc brake cylinder mounting.
      Fig 6: Locating Front Disc Brake Bushing Dust Boot
      G05202924Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL FRONT DISC BRAKE CYLINDER SLIDE BUSHING 
    1. Apply lithium soap base glycol grease to a new front disc brake cylinder slide bushing.
    2. Install the front disc brake cylinder slide bushing to the front disc brake cylinder slide pin No.2.
      Fig 7: Locating Front Disc Brake Cylinder Slide Bushing
      G05202925Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN NO.2 
    1. Apply the lithium soap base glycol grease to the sliding part and the seal surface of the slide pin No.2.
    2. Install the front disc brake cylinder slide pin No.2 to the bottom side of the cylinder mounting.
  12. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN NO.1 
    1. Apply the lithium soap base glycol grease to the sliding part and the seal surface of the slide pin No.1.
    2. Install the front disc brake cylinder slide pin No. 1.
      Fig 8: Locating Seal Surface Of Slide Pin No.1
      G05202926Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE NO.2 
  14. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE NO.1 
  15. INSTALL ANTI SQUEAL SHIM KIT FRONT 
    1. Apply disc brake grease to the anti-squeal shims and install them to each pad.
      NOTE:
      • When replacing worn pads, the anti-squeal shims must be replaced together with the pads.
      • Install the shims correctly in the proper positions and directions.
    2. Install 2 anti-squeal shims and the pad wear indicator to the inner pad.
      NOTE: Install the pad wear indicator correctly in the proper positions and directions.
  16. INSTALL DISC BRAKE PAD KIT FRONT (PAD ONLY) 
    1. Install the 2 brake pads with anti-squeal shim to the disc brake cylinder mounting.
      Fig 9: Identifying Brake Pads
      G05202927Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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