Curiosii for ever!: Car repair manuals for everyone.
Home >> Toyota Truck >> 2008 >> Highlander 2WD V6-3.5L (2GR-FE) >> Repair and Diagnosis >> Brakes and Traction Control >> Disc Brake System >> Service and Repair >> Front Brake >> Reassembly

Reassembly








BRAKE: FRONT BRAKE: REASSEMBLY

REASSEMBLY

1. INSTALL FRONT DISC






(a) 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.

2. TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG
(a) Temporarily tighten the front disc brake bleeder plug to the disc brake cylinder sub-assembly.
3. INSTALL FRONT DISC BRAKE BLEEDER PLUG CAP
(a) Install the bleeder plug cap to the front disc brake bleeder plug.
4. INSTALL PISTON SEAL
(a) Apply lithium soap base glycol grease to a new piston seal.
(b) Install the piston seal to the disc brake cylinder assembly.
NOTE: Securely install the piston seal into the groove of the disc brake cylinder.

5. INSTALL FRONT DISC BRAKE PISTON






(a) Apply lithium soap base glycol grease to the front disc brake piston and a new cylinder boot.
NOTE: Do not apply grease to the part where the cylinder boot touches the rear disc brake cylinder assembly as shown in the illustration.

(b) Install the cylinder boot to the front disc brake piston.
(c) 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.

6. INSTALL CYLINDER BOOT






(a) Install the cylinder boot to the rear disc brake cylinder assembly.

NOTICE:
- Securely install the cylinder boot into the groove of the cylinder and piston.
- Do not damage the cylinder boot.

7. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING






(a) Install the front disc brake cylinder mounting to the steering knuckle with the 2 bolts.
Torque: 104 Nm (1060 kgf-cm, 76 ft-lbf)
8. INSTALL FRONT DISC BRAKE BUSHING DUST BOOT






(a) Apply lithium soap base glycol grease to the seal surface of 2 new front disc brake bushing dust boots.
(b) Install the 2 front disc brake bushing dust boots to the front disc brake cylinder mounting.
9. INSTALL FRONT DISC BRAKE CYLINDER SLIDE BUSHING






(a) Apply lithium soap base glycol grease to a new front disc brake cylinder slide bushing.
(b) Install the front disc brake cylinder slide bushing to the No. 2 front disc brake cylinder slide pin.
10. INSTALL NO. 1 FRONT DISC BRAKE CYLINDER SLIDE PIN






(a) Apply lithium soap base glycol grease to the sliding part and the seal surface of the No. 1 front disc brake cylinder slide pin.
(b) Install the No. 1 front disc brake cylinder slide pin.
11. INSTALL NO. 2 FRONT DISC BRAKE CYLINDER SLIDE PIN






(a) Apply lithium soap base glycol grease to the sliding part and the seal surface of the No. 2 front disc brake cylinder slide pin.
(b) Install the No. 2 front disc brake cylinder slide pin to the bottom side of the front disc brake cylinder mounting.
12. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE






(a) 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.

13. INSTALL FRONT ANTI-SQUEAL SHIM






(a) Apply disc brake grease to the inside of the 2 front anti-squeal shims as shown in the illustration.

NOTICE:
- 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.





(b) 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.

14. INSTALL FRONT DISC BRAKE PAD






(a) Install the 2 brake pads with the front anti-squeal shims to the front disc brake cylinder mounting.






(b) Install the 2 anti-squeal springs to the front disc brake pads.

NOTICE:
- 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.
pro multis · Curiosii