Front Brake Pad, Brake Caliper & Brake Rotor: Reassembly

WARNING: This page is about a different car, the 2008 Toyota RAV4. However, it is still accessible from the selected car via links, so may be relevant.

HINT:

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

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.
CHECK DISC RUNOUT (See INSPECTION )
TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG
1. Install the bleeder plug to the cylinder.
  HINT:
  
  The bleeder plug will be tightened to a torque specification in the "BLEED AIR FROM BRAKE LINE" procedures.
2. Install the bleeder plug cap.
INSTALL PISTON SEAL
1. Apply lithium soap base glycol grease to a new seal.
2. Install the seal to the cylinder.
  NOTE: Securely install the piston seal into the groove of the disc brake cylinder.
INSTALL FRONT DISC BRAKE PISTON
1. Apply lithium soap base glycol grease to the piston and a new cylinder boot.
2. Install the boot to the piston.
3. Install the piston (with boot) to the cylinder.
  NOTE: Do not forcibly install the piston to the cylinder.
  
  Fig 2: Installing Front Disc Brake Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER BOOT
1. Install the cylinder boot to the cylinder. See Fig 3.
  NOTE: Securely install the cylinder boot into the groove of the disc brake cylinder.
2. Using a screwdriver, install a new set ring.
  NOTE: Do not damage the cylinder boot.
  
  HINT:
  
  Tape the screwdriver tip before use.
  
  Fig 3: Identifying Cylinder Boot
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DISC BRAKE BUSH DUST BOOT
1. Apply lithium soap base glycol grease to 2 new boots.
2. Install the 2 boots to the mounting.
  
  Fig 4: Identifying Front Disc Brake Bush Dust Boot
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN
1. Apply lithium soap base glycol grease to the pins and a new bush as shown in the illustration.
2. Install the bush to the pin (lower).
  
  Fig 5: Identifying Front Disc Brake Cylinder Slide Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the 2 pins (upper and lower) to the mounting.
  
  Fig 6: Identifying Front Disc Brake Cylinder Slide Pins
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DISC BRAKE CYLINDER MOUNTING LH
1. Install the cylinder mounting with the 2 bolts.
  Torque: 98 N*m (999 kgf*cm, 72 ft.*lbf)
INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE
1. Install the 4 plates to the mounting.
INSTALL NO. 1 PAD WEAR INDICATOR PLATE
1. Install the 2 indicator plates to the upper side of each pad.
INSTALL ANTI-SQUEAL SHIM KIT FRONT
1. w/ 275 diameter disc brake:
  1. Apply disc brake grease to both sides of each No. 1 shim.
  2. Install the No. 1 and No. 2 shims to each pad.
    NOTE:
    When replacing a worn pad, the shims must be replaced together with the pads.
    
    Install the shims in the correct positions and direction as shown in the illustration.
    Fig 8: Identifying No. 1 Pad Wear Indicator Plate (W/275 Diameter Disc Brake)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. w/ 296 diameter disc brake:
  1. Install the No. 1 and No. 2 shims to each pad.
    NOTE:
    When replacing a worn pad, the shims must be replaced together with the pads.
    
    Install the shims in the correct positions and direction as shown in the illustration.
    Fig 9: Identifying No. 1 Pad Wear Indicator Plate (W/296 Diameter Disc Brake)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DISC BRAKE PAD
1. Install the 2 disc brake pads to the mounting.
  NOTE: There should be no oil or grease on the friction surface of the pads and disc.