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Home >> Toyota Truck >> 2003 >> Highlander 2WD L4-2.4L (2AZ-FE) >> Repair and Diagnosis >> Brakes and Traction Control >> Disc Brake System >> Service and Repair >> Front

Front




FRONT BRAKE
OVERHAUL

HINT: Overhaul the RH side by the same procedures with LH side.

1. REMOVE FRONT WHEEL
2. DRAIN BRAKE FLUID

NOTICE: Do not let brake fluid remain on a painted surface. Wash it off immediately.

3. REMOVE FRONT DISC BRAKE CYLINDER SUB-ASSY
a. Remove the union bolt and gasket from the disc brake cylinder, then disconnect the flexible hose.

HINT: Gasket has 2 types: 2-piece type and 1-piece type.

b. Remove the 2 bolts and disc brake cylinder.
4. REMOVE DISC BRAKE PAD KIT FRONT (PAD ONLY)
a. Remove the 2 brake pads with anti-squeal shim.
5. REMOVE ANTI SQUEAL SHIM KIT FRONT
a. Remove the anti-squeal shim No. 1 and pad wear indicator plate from the each pad.
6. REMOVE FRONT DISC BRAKE PAD SUPPORT PLATE
7. REMOVE FRONT DISC BRAKE PAD SUPPORT PLATE
8. REMOVE FRONT DISC BRAKE CYLINDER SLIDE PIN
a. Remove the cylinder slide pins from the disc brake cylinder mounting.
9. REMOVE FRONT DISC BRAKE CYLINDER SLIDE BUSH
a. Remove the cylinder slide bush from the cylinder slide pin.
10. REMOVE FRONT DISC BRAKE BUSH DUST BOOT
a. Remove the 2 bush dust boots from the disc brake cylinder mounting.
11. REMOVE FRONT DISC BRAKE CYLINDER MOUNTING LH
a. Remove the 2 bolts and disc brake cylinder mounting LH.





12. REMOVE CYLINDER BOOT
a. Using a screwdriver, remove the set ring and cylinder boot.





13. REMOVE FRONT DISC BRAKE PISTON
a. Place a piece of cloth or similar, between the piston and the disc brake cylinder.
b. Use compressed air to remove the piston from the disc brake cylinder.

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

NOTICE: Do not spatter the brake fluid.

14. REMOVE PISTON SEAL
a. Using a screwdriver, remove the piston seal from the disc brake cylinder.
15. REMOVE FRONT DISC BRAKE BLEEDER PLUG CAP
16. REMOVE FRONT DISC BRAKE BLEEDER PLUG
17. INSPECT BRAKE CYLINDER AND PISTON
a. Check the cylinder bore and piston for rust or scoring.





18. INSPECT PAD LINING THICKNESS
a. Using a ruler, measure the pad lining thickness.
Standard thickness: 12.7 mm (0.500 inch)
Minimum thickness: 1.0 mm (0.039 inch)
19. INSPECT FRONT DISC BRAKE PAD SUPPORT PLATE
a. Make sure that they have sufficient rebound, no deformation cracks or wear, and have had all rust, dirt and foreign particles cleaned off.
20. INSPECT FRONT DISC BRAKE PAD SUPPORT PLATE
a. Make sure that they have sufficient rebound, no deformation cracks or wear, and have had all rust, dirt and foreign particles cleaned off.
21. INSPECT 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)
22. REMOVE FRONT DISC
a. Put matchmarks on the disc and the axle hub.
b. Remove the disc.
23. INSTALL FRONT DISC
a. Aligning the matchmarks, install the front disc.

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





24. INSPECT DISC RUNOUT
a. Temporarily fasten the disc with hub nuts.
Torque: 103 Nm (1,050 kgf-cm, 76 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's runout is 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 not abnormal, adjust the disc runout or grind it on a On-car brake lathe.
25. TEMPORARY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG
a. Temporarily tighten the bleeder plug to the disc brake cylinder.
26. INSTALL FRONT DISC BRAKE BLEEDER PLUG CAP
27. INSTALL PISTON SEAL
a. Apply the lithium soap base glycol grease on a new piston seal.
b. Install the piston seal to the disc brake cylinder.
28. INSTALL FRONT DISC BRAKE PISTON
a. Apply the lithium soap base glycol grease on the piston.
b. Install the piston to the disc brake cylinder smoothly.





29. INSTALL CYLINDER BOOT
a. Apply the lithium soap base glycol grease on a new cylinder boot. Install the cylinder boot to the disc brake cylinder.

HINT: Install the boot securely to the grooves of the cylinder and piston.

b. Using a screwdriver, install the set ring.

NOTICE: Do not damage the cylinder boot.

30. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING LH
a. Install the disc brake cylinder mounting LH with the 2 bolts.
Torque: 107 Nm (1,090 kgf-cm, 79 ft. lbs.)
31. INSTALL FRONT DISC BRAKE BUSH DUST BOOT
a. Apply the lithium soap base glycol grease to seal surface of 2 new bush dust boots.
b. Install the 2 bush dust boots to the disc brake cylinder mounting.
32. INSTALL FRONT DISC BRAKE CYLINDER SLIDE BUSH
a. Apply the lithium soap base glycol grease to a new cylinder slide bush.
b. Install the cylinder slide bush to the cylinder slide pin.
33. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN
a. Apply the lithium soap base glycol grease to the sliding part and the seal surface of the 2 cylinder slide pins.
b. Install the 2 cylinder slide pins to the disc brake cylinder mounting.
34. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE
35. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE
36. INSTALL ANTI SQUEAL SHIM KIT FRONT

NOTICE: When replacing worn pads, the anti-squeal shims must be replaced together with the pads.

a. Apply disc brake grease to inside of each anti-squeal shim No. 1.
b. Install anti-squeal shims on each pad.
c. Install the pad wear indicator plate to the inner pad.
37. INSTALL DISC BRAKE PAD KIT FRONT (PAD ONLY)
a. Install the inner pad with the pad wear indicator plate facing upward, and install the outer pad.

NOTICE: There should be no oil or grease adhering to the friction surfaces of the pads and the disc.

38. INSTALL FRONT DISC BRAKE CYLINDER SUB-ASSY
a. Install the disc brake cylinder with the 2 bolts.
Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.)
b. Install a new gasket and flexible hose with the union bolt.
Torque: 29 Nm (300 kgf-cm, 21 ft. lbs.)

HINT:
- Gasket has 2 types: 2-piece type and 1-piece type.
- Install the flexible hose lock securely in the lock hole in the disc brake cylinder.

39. FILL RESERVOIR WITH BRAKE FLUID
40. BLEED MASTER CYLINDER
SST 09023-00100
41. BLEED BRAKE LINE
42. CHECK FLUID LEVEL IN RESERVOIR
43. CHECK BRAKE FLUID LEAKAGE
44. INSTALL FRONT WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)

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