Front Brake Pad, Brake Caliper & Brake Rotor: Installation

1. Align the matchmarks of the disc and axle hub, and install the 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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the disc brake cylinder mounting to the steering knuckle with the 2 bolts.

   Torque: 107 N*m (1089 kgf*cm, 79 ft.*lbf) 

   Fig 2: Locating Front Disc Brake Cylinder Mounting Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply lithium soap base glycol grease to 2 new front disc brake bushing dust boots.
2. Install the 2 front disc brake bushing dust boots to the disc brake cylinder mounting.
   Fig 3: Locating Lithium Soap Base Glycol Grease Applying Area On Front Disc Brake Bushing Dust Boots

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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 4: Locating Lithium Soap Base Glycol Grease Applying Area On Front Disc Brake Cylinder Slide Bushing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply lithium soap base glycol grease to the No. 1 front disc brake cylinder slide pin and No. 2 front disc brake cylinder slide pin.
   Fig 5: Locating Lithium Soap Base Glycol Grease Applying Area On Front Disc Brake Cylinder Slide Pin

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the No. 1 front disc brake cylinder slide pin and No. 2 front disc brake cylinder slide pin to the cylinder mounting.
   Fig 6: Identifying Front Disc Brake Cylinder Slide Pin

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the 2 No. 1 front disc brake pad support plates and 2 No. 2 front disc brake pad support plates to the front disc brake cylinder mounting.
   NOTE: Be sure to install each front disc brake pad support plate in the correct position and direction.
   Fig 7: Identifying Front Disc Brake Pad Support Plate

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply disc brake shim grease to both sides of each No. 1 anti-squeal shim as shown in the illustration.
2. Install the No. 1 anti-squeal shim and No. 2 anti-squeal shim to each brake pad.
   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 shims.
   • Disc brake grease can seep 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.
     Fig 8: Locating Disc Brake Shim Grease Applying Area On Both Sides Of Each No. 1 Anti-Squeal Shim

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply disc brake grease to both sides of each No. 2 anti-squeal shim as shown in the illustration.
2. Install the pad wear indicator, No. 1 anti-squeal shim and No. 2 anti-squeal shim to each brake pad.
   NOTE:

   • When replacing worn pads, the anti-squeal shims must be replaced together with the pads.
   • Install the pad wear indicators and shims in the correct positions and directions.
   • Apply disc brake grease to the area that contacts the anti-squeal shims.
   • Disc brake grease can seep 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.
     Fig 9: Identifying Disc Brake Grease Applying Area On Both Sides Of Each No. 2 Anti-Squeal Shim

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the 2 front disc brake pads to the disc brake cylinder mounting.
   NOTE: There should be no oil or grease on the friction surfaces of the disc brake pads or the front disc.
   Fig 10: Identifying Front Disc Brake Pad

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Hold the front disc brake cylinder slide pin, and install the front disc brake cylinder assembly to the front disc brake cylinder mounting with the 2 bolts.

   Torque: 34 N*m (347 kgf*cm, 25 ft.*lbf) 

   Fig 11: Installing Front Disc Brake Cylinder Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Connect the front flexible hose to the front disc brake cylinder assembly with the union bolt and a new gasket.

   Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) 

   HINT:

   Install the flexible hose lock securely into the lock hole in the disc brake cylinder.

Torque: 103 N*m (1050 kgf*cm, 76 ft.*lbf)