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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 minimal runout.
      Fig 1: Identifying Matchmarks On Disc And Axle Hub
      G05417961Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG 
    1. Temporarily tighten the front disc brake bleeder plug to the disc brake cylinder sub-assembly.
  3. INSTALL FRONT DISC BRAKE BLEEDER PLUG CAP 
    1. Install the bleeder plug cap to the front disc brake bleeder plug.
  4. INSTALL PISTON SEAL 
    1. Apply a light layer of lithium soap base glycol grease to the entire circumference of a new piston seal.
    2. Install the piston seal to the disc brake cylinder assembly.
      NOTE: Securely install the piston seal into the groove of the disc brake cylinder.
      Fig 2: Applying Light Layer Of Lithium Soap Base Glycol Grease To Entire Circumference Of Piston Seal
      G06116830Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL FRONT DISC BRAKE PISTON 
    1. Apply a light layer of lithium soap base glycol grease to the entire circumference of a new cylinder boot.
    2. Install the cylinder boot to the front disc brake piston.
    3. Apply a light layer of lithium soap base glycol grease to the contact surfaces of the front disc brake piston, and install the front disc brake piston to the disc brake cylinder assembly.
      NOTE: Do not install the front disc brake piston forcibly in the disc brake cylinder assembly.
      Fig 3: Applying Light Layer Of Lithium Soap Base Glycol Grease To Entire Circumference Of Cylinder Boot
      G06116831Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL CYLINDER BOOT 
    1. Install the cylinder boot to the front disc brake cylinder assembly as shown in the illustration.
      NOTE:
      • Securely install the cylinder boot into the groove of the cylinder and piston.
      • Do not damage the cylinder boot.
        Fig 4: Installing Cylinder Boot To Front Disc Brake Cylinder Assembly
        G06116832Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING 
    1. Install the front disc brake cylinder mounting to the steering knuckle with the 2 bolts.

      Torque: 104 N*m (1060 kgf*cm, 76 ft.*lbf) 

      Fig 5: Locating Front Disc Brake Cylinder Mounting Bolts
      G05417957Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL FRONT DISC BRAKE BUSHING DUST BOOT 
    1. Apply a light layer of lithium soap base glycol grease to the contact and inner surfaces of 2 new front disc brake bushing dust boots.

      HINT:

      Apply at least 0.3 g (0.01 oz.) of lithium soap base glycol grease to each front disc brake bushing dust boot.

      Fig 6: Identifying Grease Applying Area To Front Disc Brake Bushing Dust Boots
      G06116834Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 2 front disc brake bushing dust boots to the front disc brake cylinder mounting.
      Fig 7: Identifying Front Disc Brake Bushing Dust Boots
      G06116835Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL FRONT DISC BRAKE CYLINDER SLIDE BUSHING 
    1. Apply a light layer of lithium soap base glycol grease to the contact surface of the No. 2 front disc brake cylinder slide pin.
    2. Install a new front disc brake cylinder slide bushing to the No. 2 front disc brake cylinder slide pin.
      Fig 8: Identifying Lithium Soap Base Glycol Grease Applying Area
      G06116836Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL NO. 1 FRONT DISC BRAKE CYLINDER SLIDE PIN 
    1. Apply a light layer of 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: Identifying Lithium Soap Base Glycol Grease Applying Area
      G06116837Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the No. 1 front disc brake cylinder slide pin to the front disc brake cylinder mounting.
      Fig 10: Identifying No. 1 Front Disc Brake Cylinder Slide Pin
      G06116838Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL NO. 2 FRONT DISC BRAKE CYLINDER SLIDE PIN 
    1. Apply a light layer of lithium soap base glycol grease to the sliding part and the seal surface of the No. 2 front disc brake cylinder slide pin.
      Fig 11: Identifying Lithium Soap Base Glycol Grease Applying Area
      G06116839Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the No. 2 front disc brake cylinder slide pin to the front disc brake cylinder mounting.
      Fig 12: Identifying No. 2 Front Disc Brake Cylinder Slide Pin
      G06116840Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE 
    1. Install the 4 front disc brake pad support plates to the front disc brake cylinder mounting as shown in the illustration.
      NOTE: Be sure to install each front disc brake pad support plate to the correct position and direction.
      Fig 13: Identifying Front Disc Brake Pad Support Plates Installation Position
      G05417974Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL FRONT ANTI-SQUEAL SHIM 
    1. Apply disc brake grease to the inside of the 2 front anti-squeal shims as shown in the illustration.
      Fig 14: Identifying Disc Brake Grease Application Area
      G05417975Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • When replacing worn pads, the front 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 front anti-squeal shim.
      • Disc brake grease can come out slightly from the area where the front anti-squeal shim is installed.
      • Make sure that disc brake grease is not applied onto the lining surface.
    2. Install the 2 front anti-squeal shims and the 2 pad wear indicators to the pads.
      NOTE: Install the pad wear indicators in the correct positions and directions.
      Fig 15: Identifying Front Anti-Squeal Shims And Pad Wear Indicators
      G05417976Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL FRONT DISC BRAKE PAD 
    1. Install the 2 brake pads with the front anti-squeal shims to the front disc brake cylinder mounting.
      Fig 16: Identifying Anti-Squeal Shims
      G05417951Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. 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 springs at the same time.
      • Be sure to install the anti-squeal springs into the front disc brake pad installation holes as far as they will go.
        Fig 17: Locating Anti-Squeal Springs
        G05417978Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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