Toyota Corolla 1988-1997 Repair Guide

Brake Caliper

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REMOVAL & INSTALLATION




CAUTION
Brake pads may contain asbestos, which has been determined to be a cancer causing agent. Never clean the brake surfaces with compressed air! Avoid inhaling any dust from any brake surfaces. When cleaning brake surfaces, use a commercially available brake cleaning fluid.

  1. Raise and safely support the rear of the vehicle on jackstands. Block the front wheels. Remove the rear wheels and install two lug nuts hand tight to hold the rotor in place.
  2.  
  3. Place a container under the caliper assembly to catch spillage. Disconnect the union bolt (and remove gaskets) holding the brake hose to the caliper. Plug or tape the hose immediately.
  4.  
  5. Disconnect parking brake cable from the caliper assembly.
  6.  
  7. Remove the caliper mounting bolts. Remove the brake caliper.
  8.  

To install:
  1. Install brake pads in the caliper if necessary.
  2.  
  3. Connect the parking brake cable.
  4.  
  5. Install the caliper so that the pad protrusion fits into the piston stopper groove. Insert the cylinder carefully so the boot is not wedged.
  6.  
  7. Install the mounting bolts and tighten it to 14 ft. lbs. (20 Nm).
  8.  
  9. Install the parking brake clip.
  10.  
  11. Connect the brake hose to the caliper, install new gaskets. Tighten the union bolt to 22 ft. lbs. (29 Nm).
  12.  
  13. Install the rear wheels.
  14.  
  15. Fill the brake reservoir with brake fluid and bleed brake system.
  16.  


WARNING
Clean, high quality brake fluid is essential to the safe and proper operation of the brake system. You should always buy the highest quality brake fluid that is available. If the brake fluid becomes contaminated, drain and flush the system, then refill the master cylinder with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded.

  1. Adjust the parking brake lever travel as follows:
    1. Pull the parking brake lever a few times.
    2.  
    3. Release the parking brake lever.
    4.  
    5. Depress the brake pedal several times and adjust the rear brakes automatically.
    6.  
    7. Check that the parking brake crank touches the stopper pin.
    8.  
    9. Pull the parking brake lever all the way up and count the number of clicks. The correct specification for parking brake lever travel is at 44.1 lbs. of pull 5-8 clicks. If necessary adjust the parking brake lever travel at the parking brake lever assembly.
    10.  

  2.  

OVERHAUL



The use of the correct special tools or their equivalent is REQUIRED for this procedure.

  1. Remove the slide bushings and dust boots.
  2.  
  3. Remove the set ring and dust boot from the caliper piston.
  4.  
  5. Remove the caliper piston (turn piston counterclockwise and remove) from the bolt.
  6.  
  7. Remove the seal from the inside of the caliper bolt.
  8.  
  9. Install a special tool SST 09756-00010 or its equivalent onto the adjusting bolt and lightly tighten it with a 14mm socket. Do not overtighten the tool; damage to the spring may result.
  10.  


WARNING
Always use this tool during disassembly. The spring may fly out, causing personal injury and/or damage to the caliper bore.

  1. Remove the snapring from the caliper bore.
  2.  
  3. Carefully remove the adjusting bolt and disassemble it.
  4.  
  5. Remove the parking brake strut.
  6.  
  7. Remove the cable support bracket, then remove the torsion spring from the parking brake crank.
  8.  
  9. Remove the parking brake crank from the caliper.
  10.  
  11. Remove the parking brake crank boot by tapping it lightly on the metal portion of the boot. Do not remove the boot unless it is to be replaced.
  12.  
  13. Use a pin punch to tap out the stopper pin.
  14.  
  15. Check all the parts for wear, scoring, deterioration, cracking or other abnormal conditions. Corrosion - generally caused by water in the system - will appear as white deposits on the metal. Pay close attention to the condition of the inside of the caliper bore and the outside of the piston. Any sign of corrosion or scoring requires new parts; do not attempt to clean or resurface either face.
  16.  
  17. The caliper overhaul kit will, at minimum, contain new seals and dust boots. A good kit will contain a new piston as well, but you may have to buy the piston separately. Any time the caliper is disassembled, a new piston is highly recommended in addition to the new seals.
  18.  
  19. Clean all the components to be reused with an aerosol brake solvent and dry them thoroughly. Take any steps necessary to eliminate moisture or water vapor from the parts.
  20.  
  21. Coat all the caliper components with fresh brake fluid from a new can.
  22.  

Some repair kits come with special assembly lubricant for the piston and seal. Use this lubricant according to directions with the kit.

  1. Install the stopper pin into the caliper until the pin extends 1 inch (25mm).
  2.  
  3. Install the parking brake crank boot. Use a 24mm socket to tap the boot to the caliper.
  4.  
  5. Install the parking brake crank onto the caliper. Make certain the crank boot is securely matched to the groove of the crank seal.
  6.  
  7. Install the cable support bracket. Press the surface of the bracket flush against the wall of the caliper and tighten the bolt to 34 ft. lbs. (46 Nm).
  8.  
  9. Check that the clearance between the parking brake crank and the cable support is 6mm.
  10.  
  11. Install the torsion spring.
  12.  
  13. Inspect the crank sub-assembly, making sure it touches the stopper pin.
  14.  
  15. Install the parking brake strut. Before adjusting the strut, adjust the rollers of the needle roller bearing so they do not catch on the caliper bore.
  16.  
  17. Install a new O-ring on the adjusting bolt.
  18.  
  19. Install the stopper, plate, spring, and spring retainer onto the adjusting bolt. Using a special tool or equivalent hand tighten the assembly. Make certain the inscribed portion of the stopper faces upward. Align the notches of the spring retainer with the notches of the stopper.
  20.  
  21. Install the adjusting bolt assembly into the cylinder.
  22.  
  23. Install snapring into the bore. Make certain the gap in the ring faces toward the bleeder side.
  24.  
  25. Pull up on the adjusting bolt by hand to make certain it does not move.
  26.  
  27. Move the parking brake crank by hand and make certain adjusting bolt moves smoothly.
  28.  
  29. Install a new piston seal in the caliper bore.
  30.  
  31. Install the piston into the caliper bore. Using a special tool or its equivalent, slowly screw the piston clockwise until it will not descend any further.
  32.  
  33. Align the center of the piston stopper groove with the positioning marks of the caliper bore.
  34.  
  35. Install the piston dust boot and its set ring.
  36.  
  37. Install a new boot on the main (upper) caliper pin. Use a 21mm socket to press in the new boot.
  38.  
  39. Install the slide bushings and boots onto the caliper.
  40.  

 
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