Front Brake Pad, Brake Caliper & Brake Rotor: Reassembly

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.

Fig 1: Identifying Matchmarks On Disc And Axle Hub
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG
1. Temporarily tighten the front disc brake bleeder plug to the disc brake cylinder sub-assembly.
INSTALL FRONT DISC BRAKE BLEEDER PLUG CAP
1. Install the bleeder plug cap to the front disc brake bleeder plug.
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.
INSTALL FRONT DISC BRAKE PISTON (for TMC Made)
1. Apply lithium soap base glycol grease to the piston and a new cylinder boot.
2. Install the cylinder boot to the piston.
  
  Fig 2: Locating Cylinder Boot And Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the piston to the disc brake cylinder assembly.
NOTE: Do not install the piston forcibly in the cylinder assembly.
INSTALL CYLINDER BOOT (for TMC Made)
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 3: Installing Cylinder Boot
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a screwdriver, install a new set ring.
NOTE:
- Install the set ring securely to the grooves of the cylinder boot.
- Do not damage the cylinder boot.
HINT:

Tape the screwdriver tip before use.
INSTALL CYLINDER BOOT (for TMMK Made)
1. Apply lithium soap base glycol grease to the piston and a new cylinder boot.
2. Install the cylinder boot to the piston as shown in the illustration.
  
  Fig 4: Installing Cylinder Boot To Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DISC BRAKE PISTON (for TMMK Made)
1. Install the cylinder boot to the cylinder assembly.
  
  Fig 5: Installing Cylinder Boot To Cylinder Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Install the boot securely to the grooves of the cylinder.
2. Push in the piston by hand and install the boot seal onto the grooves of the piston.
NOTE: Install the boot securely to the grooves of the piston.
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: Installing Bushing Dust Boots To Front Disc Brake Cylinder Mounting
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 No. 2 front disc brake cylinder slide pin.
  
  Fig 7: Locating Lithium Soap Base Glycol Grease Apply Area
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 FRONT DISC BRAKE CYLINDER SLIDE PIN
1. Apply lithium soap base glycol grease to the sliding part and the seal surface of the No. 2 front disc brake cylinder slide pin.
2. Install the No. 2 front disc brake cylinder slide pin to the bottom side of the cylinder mounting.
  
  Fig 8: Locating No. 2 Front Disc Brake Cylinder Slide Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 FRONT DISC BRAKE CYLINDER SLIDE PIN
1. Apply lithium soap base glycol grease to the sliding part and the seal surface of the No. 1 front disc brake cylinder slide pin.
  
  Fig 9: Applying Lithium Soap Base Glycol Grease To Sliding Part
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the No. 1 front disc brake cylinder slide pin.
  
  Fig 10: Locating No. 1 Front Disc Brake Cylinder Slide Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DISC BRAKE CYLINDER MOUNTING
1. Install the cylinder mounting with the 2 bolts.
  Torque: 107 N*m (1,090 kgf*cm, 79 ft.*lbf)
  
  Fig 11: Locating Cylinder Mounting Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE
INSTALL FRONT ANTI-SQUEAL SHIM
1. Apply disc brake grease to the anti-squeal shims.
  
  Fig 12: Applying Disc Brake Grease To Anti-Squeal Shims
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - When replacing worn pads, the anti-squeal shims must be replaced together with the pads.
  - Install the shims in the correct positions and directions.
  - Apply disc brake grease to the area that contacts the anti-squeal shim.
  - Disc brake grease can come out slightly from the area where the anti-squeal shim is installed.
  - Make sure that disc brake grease is not applied onto the lining surface.
2. Install the 2 anti-squeal shims and the 2 pad wear indicators to each pad.
  
  Fig 13: Locating Anti-Squeal Shims
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NOTE: Install the pad wear indicators in the correct positions and directions.
INSTALL FRONT BRAKE PAD
1. Install the 2 brake pads with anti-squeal shims to the disc brake cylinder mounting.
INSTALL ANTI-SQUEAL SPRING (w/ Anti-squeal Spring)
1. Install the 2 anti-squeal springs to the front disc brake pads.
NOTE:
- When replacing the front brake pads with new ones, make sure to replace the anti-squeal spring at the same time.
- Be sure the install the anti-squeal springs into the front disc brake pad installation holes as far as they will go.