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Front Brake: Overhaul

WARNING: This page is about a different car, the 2004 Toyota Camry Solara. However, it is still accessible from the selected car via links, so may be relevant.

HINT:

  1. REMOVE FRONT WHEEL 
  2. DRAIN BRAKE FLUID 
    NOTE: Wash brake fluid off immediately if it adheres to any painted surface. 
  3. DISCONNECT FRONT FLEXIBLE HOSE 
    1. Remove the union bolt and the 2 gaskets from the disc brake cylinder sub- assy, then disconnect the flexible hose.
  4. REMOVE FRONT DISC BRAKE CYLINDER SUB-ASSY 
    1. Hold the front disc brake cylinder slide pin (No.1), side pin (No.2) and remove the 2 bolts.
      Fig 1: Removing Front Disc Brake Cylinder Sub-Assy
      G02585254Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE DISC BRAKE PAD KIT FRONT (PAD ONLY) 
    1. Remove the 2 disc brake pads with anti squeal shims from the front disc brake cylinder mounting LH.
  6. REMOVE ANTI SQUEAL SHIM KIT FRONT 
    1. Remove the 2 anti squeal shims from each pad.
    2. Using a screwdriver, remove the pad wear indicator plates from each pad.
  7. REMOVE FRONT DISC BRAKE PAD SUPPORT PLATE 
    1. Remove the front disc brake pad support plate (No.1) and front disc brake pad support plate (No.2) from the front disc brake cylinder mounting LH.
  8. REMOVE FRONT DISC BRAKE CYLINDER SLIDE PIN 
    1. Remove the front disc brake cylinder slide pin (No.1) and front disc brake cylinder slide pin (No.2) from the front disc brake cylinder mounting LH.
      Fig 2: Removing Front Disc Brake Cylinder Slide Pins
      G02585255Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE FRONT DISC BRAKE CYLINDER SLIDE BUSH 
    1. Using a screwdriver, remove the front disc brake cylinder slide bush from the front disc brake cylinder slide pin (No.2).
    NOTE: Do not damage the front disc brake cylinder slide pin (No.2). 
    Fig 3: Removing Front Disc Brake Cylinder Slide Bush
    G02585256Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE FRONT DISC BRAKE CYLINDER MOUNTING 
    1. Remove the 2 bolts and front disc brake cylinder mounting LH.
      Fig 4: Removing Front Disc Brake Cylinder Mounting (LH)
      G02585257Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE FRONT DISC BRAKE BUSH DUST BOOT 
    1. Hold the front disc brake cylinder mounting LH in the vise through the soft jaws.
    2. Using a screwdriver and hammer, remove the 2 front disc brake bush dust boots from the front disc brake cylinder mounting LH.
      Fig 5: Removing Front Disc Brake Bush Dust Boot
      G02585258Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE CYLINDER BOOT 
    1. Using a screwdriver, remove the set ring and cylinder boot.
    NOTE: Do not damage the piston groove and cylinder groove. 
    Fig 6: Removing Set Ring & Cylinder Boot
    G02585259Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE FRONT DISC BRAKE PISTON 
    1. Place a shop rag, between the front disc brake piston and the disc brake cylinder sub-assy.
    2. Use compressed air to remove the front disc brake piston from the disc brake cylinder sub-assy.
      3. Fig 7: Removing Front Disc Brake Piston
      G02585260Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    CAUTION: Do not place your fingers in front of the piston when using compressed air. 
    NOTE: Do not spatter the brake fluid. 
  14. REMOVE PISTON SEAL 
    1. Using a screwdriver, remove the piston seal from the front disc brake cylinder sub-assy.
    NOTE: Do not damage the inner cylinder and cylinder groove. 
    Fig 8: Removing Piston Seal
    G02585261Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE FRONT DISC BRAKE BLEEDER PLUG 
    1. Remove the front disc brake bleeder plug from the front disc brake cylinder sub-assy.
  16. REMOVE FRONT DISC BRAKE BLEEDER PLUG CAP 
    1. Remove the bleeder plug cap from the front disc brake bleeder plug.
  17. INSPECT BRAKE CYLINDER AND PISTON 
    1. Check the brake cylinder bore and front disc brake piston for rust or scoring. If necessary, replace the brake cylinder and piston.
  18. INSPECT PAD LINING THICKNESS 
    1. Using a ruler, measure the pad lining thickness.
      • Standard thickness:  12.0 mm (0.472 in.)
      • Minimum thickness:  1.0 mm (0.039 in.)

    If the pad lining thickness is equal to the minimum thickness or less, replace the brake pad.

    Fig 9: Measuring Pad Lining Thickness
    G02585262Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSPECT FRONT DISC BRAKE PAD SUPPORT PLATE 
    1. Inspect the front disc brake pad support plate (No.1) and front disc brake pad support plate (No.2).

    HINT:

    Make sure that both have sufficient rebound, have no deformation, cracks or wear, and that all rust and dirt is cleaned off.

    If necessary, replace the brake pad support plate.

  20. INSPECT DISC THICKNESS 
    1. Using a micrometer, measure the disc thickness.
      • Standard thickness:  28.0 mm (1.102 in.)
      • Minimum thickness:  26.0 mm (1.024 in.)

    If the disc thickness is less than the minimum, replace the disc.

    Fig 10: Measuring Disc Thickness
    G02585263Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE FRONT DISC 
    1. Place matchmarks on the front disc and the axle hub.
      2. Fig 11: Placing Matchmarks On Front Disc & Axle Hub
      G02585264Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the front disc.
  22. INSTALL FRONT DISC 
    1. Aligning the matchmarks, install the front disc.

    HINT:

    When replacing the disc with a new one, select the installation position where the front disc has the minimum runout.

  23. INSPECT DISC RUNOUT 
    1. Check the bearing play in the axial direction and check for the axle hub runout (see ON-VEHICLE INSPECTION ).
    2. Temporarily fasten the front disc together with the hub nuts.

      Torque:  103 N.m (1,050 kgf.cm, 76 ft.lbf)

    3. Using a dial indicator, measure the disc runout 10 mm (0.39 in.) away from the outer edge of the front disc.
      Fig 12: Checking Disc Runout
      G02585265Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Maximum disc runout:  0.05 mm (0.0020 in.)

    If the runout exceeds the maximum value, change the installation positions of the disc and axle so that the runout will become minimal. If the runout exceeds the maximum even when the installation positions are changed, grind the disc. If the disc thickness is less than the minimum, replace the front disc.

  24. TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG 
    1. Temporarily install the front disc brake bleeder plug to the front disc brake cylinder sub-assy.
  25. INSTALL FRONT DISC BRAKE BLEEDER PLUG CAP 
    1. Install the bleeder plug cap to the front disc brake bleeder plug.
  26. INSTALL PISTON SEAL 
    1. Apply lithium soap base glycol grease to a new piston seal.
    2. Install the piston seal to the front disc brake cylinder sub-assy.
  27. INSTALL FRONT DISC BRAKE PISTON 
    1. Apply lithium soap base glycol grease to the front disc brake piston and new cylinder boot.
      Fig 13: Applying Lithium Soap Base Glycol Grease
      G02585266Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the cylinder boot to the front disc brake piston.
    3. Install the front disc brake piston to the front disc brake cylinder sub-assy.
    NOTE: Do not install the piston forcibly in the front disc brake cylinder sub-assy. 
  28. INSTALL CYLINDER BOOT 
    1. Install a new cylinder boot to the front disc brake cylinder sub-assy.
      Fig 14: Installing Cylinder Boot
      G02585267Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Install the boot securely to the grooves of the cylinder and piston. 
      • Do not damage the cylinder boot. 
    2. Using a screwdriver, install the set ring.
    NOTE: Do not damage the cylinder boot. 
  29. INSTALL FRONT DISC BRAKE BUSH DUST BOOT 
    1. Hold the front disc brake cylinder mounting LH in the vise through the soft jaws.
    2. Place the front disc brake cylinder mounting LH in the vise.
    3. Apply lithium soap base glycol grease to the sealing surface of 2 new front disc brake bush dust boots (see FRONT BRAKE ).
    4. Using a socket wrench (19 mm) and hammer, drive the 2 front disc brake bush dust boots to the front disc brake cylinder mounting LH.
      Fig 15: Installing Front Disc Brake Bush Dust Boots
      G02585268Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. INSTALL FRONT DISC BRAKE CYLINDER SLIDE BUSH 
    1. Apply lithium soap base glycol grease to a new front disc brake cylinder slide bush (see FRONT BRAKE ).
    2. Install the cylinder slide bush to the bottom side of the front disc brake cylinder slide pin (No.2).
  31. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN 
    1. Apply lithium soap base glycol grease to the sliding part and the sealing surface of the front disc brake cylinder slide pin (No.1) and front disc brake cylinder slide pin (No.2).
    2. Install the front disc brake cylinder slide pin (No.1) and front disc brake cylinder slide pin (No.2) to the front disc brake cylinder mounting LH.
    3. Install the front disc brake cylinder slide pin (No.2) to the front disc brake cylinder mounting LH.
      Fig 16: Installing Front Disc Brake Cylinder Slide Pin
      G02585269Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING 
    1. Install the front disc brake cylinder mounting with the 2 bolts.

      Torque:  107 N.m (1,090 kgf.cm, 79 ft.lbf)

      Fig 17: Installing Front Disc Brake Cylinder Mounting
      G02585270Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE 
    1. Install the front disc brake pad support plate (No.1) and front disc brake pad support plate (No.2) to the front disc brake cylinder mounting LH.
  34. INSTALL ANTI SQUEAL SHIM KIT FRONT 
    1. Apply disc brake grease to the anti squeal shims and install them to each pad (see FRONT BRAKE ).
      NOTE:
      • When replacing worn pads, the anti squeal shims must be replaced together with the pads. 
      • Install the shims in the correct position and direction. 
    2. Install the pad wear indicator plates to the each pad.
  35. INSTALL DISC BRAKE PAD KIT FRONT (PAD ONLY) 
    1. Install the disc brake pad kit front to the front disc brake cylinder mounting LH.
      NOTE:
      • There should be no oil or grease on the friction surface of the pads and the disc. 
      • Brake pads are installed with indicator plates facing upward. 
  36. INSTALL FRONT DISC BRAKE CYLINDER SUB-ASSY 
    1. Install the front disc brake cylinder sub-assy with the 2 bolts.

      Torque:  34 N.m (350 kgf.cm, 25 ft.lbf)

      Fig 18: Installing Front Disc Brake Cylinder Sub-Assy
      G02585271Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. INSTALL FRONT FLEXIBLE HOSE 
    1. Install 2 new gaskets and flexible hose with the union bolt.

      Torque:  29 N.m (300 kgf.cm, 22 ft.lbf)

    NOTE: Install the flexible hose lock securely in the lock hole in the disc brake cylinder. 
  38. FILL RESERVOIR WITH BRAKE FLUID (SEE  PROBLEM SYMPTOMS TABLE  ) 
  39. BLEED MASTER CYLINDER (SEE  PROBLEM SYMPTOMS TABLE  ) 

    SST 09023-00101

  40. BLEED BRAKE LINE (SEE  PROBLEM SYMPTOMS TABLE  ) 
  41. CHECK FLUID LEVEL IN RESERVOIR (SEE  PROBLEM SYMPTOMS TABLE  ) 
  42. CHECK BRAKE FLUID LEAKAGE 
  43. INSTALL FRONT WHEEL 

    Torque:  103 N.m (1,050 kgf.cm, 76 ft.lbf)

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