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Disc Brake System: Service and Repair

FRONT BRAKE (4WD AND PRE RUNNER)





COMPONENTS

OVERHAUL

HINT: The overhaul procedure for the RH side is the same as that for the LH side.

1. REMOVE FRONT WHEEL
2. DRAIN BRAKE FLUID

NOTICE: Immediately wash off any brake fluid that comes into contact with any painted surfaces.





3. REMOVE FRONT DISC BRAKE ANTI RATTLE W/HOLE PIN
a. Remove the 2 pin hold clips, then remove the 2 anti-rattle w/ hole pins from the disc brake cylinder.
b. Remove the anti-rattle spring from the disc brake pad.
4. REMOVE DISC BRAKE PAD KIT FRONT (PAD ONLY)
a. Remove the 2 disc brake pads with anti-squeal shim from the disc brake cylinder.
5. REMOVE ANTI SQUEAL SHIM KIT FRONT
a. Remove the 2 anti-squeal shims from each of the disc brake pads.





6. REMOVE DISC BRAKE CYLINDER ASSEMBLY LH
a. Using SST, disconnect the brake tube from the disc brake cylinder.
SST 09023-00101

HINT: Use a container to collect the brake fluid as it drains out.





b. Remove the 2 bolts and disc brake cylinder.





7. REMOVE CYLINDER BOOT
a. Using a screwdriver, remove the 4 cylinder boots from the caliper.





8. REMOVE FRONT DISC BRAKE PISTON
a. Prepare a wooden plate to hold the pistons.





b. Place the plate between the pistons and insert a pad into one side.
c. Use compressed air and remove the pistons one side at a time from the cylinder.

CAUTION: Do not place your fingers in front of the pistons when using compressed air.





9. REMOVE PISTON SEAL
a. Using a screwdriver, remove the 4 piston seals from the cylinder.
10. REMOVE FRONT DISC BRAKE BLEEDER PLUG
a. Remove the bleeder plug cap and bleeder plug from the disc brake cylinder.
11. INSPECT BRAKE CYLINDER AND PISTON
a. Check the cylinder bore and piston for rust and scoring.





12. CHECK PAD LINING THICKNESS
a. Using a ruler, measure the pad lining thickness.
Standard thickness: 11.5 mm (0.453 inch)
Minimum thickness: 1.0 mm (0.039 inch)





13. CHECK DISC THICKNESS
a. Using a micrometer, measure the disc thickness.
Standard thickness: 28.0 mm (1.102 inch)
Minimum thickness: 26.0 mm (1.024 inch)
14. REMOVE FRONT DISC
a. Make matchmarks on the disc and the axle hub.
b. Remove the front disc.
15. INSTALL FRONT DISC
a. Aligning the matchmarks, install the front disc.

HINT: When replacing the disc with a new one, select the installation position where the disc has the minimum run out.





16. INSPECT DISC RUNOUT
a. Provisionally fasten the disc with the hub nuts.
Torque: 113 Nm (1,152 kgf-cm, 83 ft. lbs.)
b. Using a dial indicator, measure the disc runout 10 mm (0.39 inch) away from the outer edge of the disc.
Maximum disc runout: 0.05 mm (0.0020 inch)
c. If the disc runout is the maximum value or greater, check the bearing play in the axial direction and check the axle hub runout. If the bearing play and axle hub runout are normal, adjust the disc runout or grind it on an on-car brake lathe.
17. TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG
a. Provisionally tighten the bleeder plug to the disc brake cylinder.
b. Install the bleeder plug cap onto the bleeder plug.
18. INSTALL PISTON SEAL
a. Apply lithium soap base glycol grease to 4 new piston seals.
b. Install the 4 piston seals onto the disc brake cylinder.
19. INSTALL FRONT DISC BRAKE PISTON
a. Apply lithium soap base glycol grease to the 4 disc brake pistons.
b. Install the 4 disc brake pistons onto the disc brake cylinder.

NOTICE: Do not install the disc brake piston into the disc brake cylinder forcibly.

20. INSTALL CYLINDER BOOT
a. Apply lithium soap grease glycol grease to 4 new cylinder boots.
b. Install the 4 cylinder boots onto the disc brake cylinder.

HINT: Install the cylinder boot securely onto the grooves of the disc brake cylinder and piston.





21. INSTALL DISC BRAKE CYLINDER ASSEMBLY LH
a. Install the disc brake cylinder assembly with the 2 bolts.
Torque: 123 Nm (1,254 kgf-cm, 91 ft. lbs.)





b. Using SST, connect the brake tube to the disc brake cylinder.
SST 09023-00101
Torque: 15.2 Nm (155 kgf-cm, 11 ft. lbs.)
22. INSTALL ANTI SQUEAL SHIM KIT FRONT

NOTICE: If necessary, replace the anti-squeal shim kit when replacing the brake pad.

a. Install the anti-squeal shims on to each brake pad.
23. INSTALL DISC BRAKE PAD KIT FRONT (PAD ONLY)
a. Install the 2 disc brake pads with anti-squeal shim onto the disc brake cylinder.

NOTICE: There should be no oil or grease on the friction surfaces of the brake pads and the front disc.





24. INSTALL FRONT DISC BRAKE ANTI RATTLE W/HOLE PIN
a. Install the 2 anti rattle w/ hole pins and anti-rattle spring onto the disc brake cylinder.

HINT: The anti-rattle spring is installed onto the lower anti-rattle w/ hole pin.

b. Install the 2 new pin hold clips with the anti-rattle w/ hole pin.

NOTICE: Be sure to install the pin hold clip with the handle facing to the vehicle center.

25. FILL RESERVOIR WITH BRAKE FLUID (W/VSC)
26. FILL RESERVOIR WITH BRAKE FLUID (W/O VSC)
27. BLEED MASTER CYLINDER (W/O VSC)
SST 09023-00101
28. BLEED BRAKE LINE (W/VSC)
29. BLEED BRAKE LINE (W/O VSC)
30. CHECK FLUID LEVEL IN RESERVOIR (W/ VSC)
31. CHECK FLUID LEVEL IN RESERVOIR (W/O VSC)
32. CHECK FOR BRAKE FLUID LEAKAGE
33. INSTALL FRONT WHEEL
Torque: 113 Nm (1,152 kgf-cm, 83 ft. lbs.)
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