Toyota Pick-ups/Land Cruiser/4Runner 1970-1988

Brake Caliper

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REMOVAL & INSTALLATION



1975-83 2WD Pick-Up (Exc. C & C), 1975-88 4WD Pick-Up and 4Runner and

1975-88 Land Cruiser


CAUTION
Brake shoes 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 surface! When cleaning brake surfaces, use a commercially available brake cleaning fluid.

  1. Jack up the front of the truck, support it on jackstands, and remove the front wheel.
  2.  
  3. Pull out the two wire clips at the ends of the pad pins.
  4.  
  5. Pull out the pads and anti-rattle spring.
  6.  
  7. Remove the brake pads. On all 2WD Pick-ups and 1988 4WD Pick-ups and 4Runners, lift out the anti-squeal shims .
  8.  
  9. Plug the vent hole on the master cylinder cap to prevent fluid leak. Unbolt the brake line from the caliper, being careful not to deform the fittings.
  10.  
  11. Remove the 2 caliper mounting bolts, and remove the caliper.
  12.  

To install:
  1. Position the caliper and install the mounting bolts. Tighten the caliper mounting bolts to 67-87 ft. lbs. on 2WD Pick-Ups, 55-75 ft. lbs. on 1975-85 4WD Pick-Ups and 90 ft. lbs. on 1986-88 4WD Pick-Ups and all Land Cruisers. Be certain to position the shims correctly.
  2.  
  3. Install the brake pads.
  4.  
  5. Install the wheel and lower the truck. Bleed the brakes and road test the vehicle.
  6.  

1975-83 2WD Pick-Up (C & C), 1984-88 2WD Pick-Up W/FS17-Type Brakes and 1984-88 2WD Pick-Up W/PD60-Type Brakes

Caliper removal procedures for these models are detailed within the respective "Brake Pad Removal" sections. On models with FS17-type brakes, simply remove the other mounting bolt. Additionally, on all models, disconnect the brake hydraulic line.

OVERHAUL



See Figures 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11 and 12

1975-83 2WD Pick-Up (Exc. C & C), 1975-88 4WD Pick-Up and 4Runner and

1975-88 Land Cruiser

  1. Raise the front of the truck and support with safety stands. Remove the wheels.
  2.  
  3. Remove the caliper.
  4.  
  5. Carefully pry the dust boot set ring out of the caliper. Remove the dust boot.
  6.  
  7. Insert a piece of wood about 1 / 2 in. thick between the caliper pistons.
  8.  
  9. Apply compressed air to the brake line union to force the piston out of its bore. Be careful; the piston may come out forcefully!
  10.  
  11. Remove the piston seal from the caliper cylinder bore. Check the piston and cylinder bore for wear and/or corrosion. Replace components as necessary.
  12.  


CAUTION
Do not loosen the four bolts holding the two halves of the caliper together.

To assemble:
  1. Coat all components with clean brake fluid or lithium soap base glycol grease.
  2.  
  3. Install the piston seal and then the piston into the caliper cylinder bore. Seat the piston in the bore with your fingers.
  4.  
  5. Fit the boot into the groove in the cylinder bore and press in the set ring.
  6.  
  7. Install the caliper and brake pads.
  8.  
  9. Install the wheels and lower the truck. Bleed the brakes and road test the vehicle.
  10.  

1975-83 2WD Pick-Up (C & C)

1984-88 2WD Pick-Up W/FS17-Type Brakes 1984-88 2WD Pick-Up W/PD60-Type Brakes

See Figures 13, 14, 15 and 16

  1. Raise the front of the truck and support with safety stands. Remove the wheels.
  2.  
  3. Remove the caliper.
  4.  
  5. Remove the slide bushing (2 on PD60), 2 pin dust boots (4 on PD60) and 2 collars (PD60 only).
  6.  
  7. Carefully pry the dust boot set ring out of the caliper. Remove the dust boot.
  8.  
  9. Insert a piece cloth or rag between the caliper claw and the piston.
  10.  
  11. Apply compressed air to the brake line union to force the piston out of its bore. Be careful; the piston may come out forcefully!
  12.  
  13. Remove the piston seal from the caliper cylinder bore. Check the piston and cylinder bore for wear and/or corrosion. Replace components as necessary.
  14.  

To assemble:
  1. Coat all components with clean brake fluid or lithium soap base glycol grease.
  2.  
  3. Install the piston seal and then the piston into the caliper cylinder bore. Seat the piston in the bore with your fingers.
  4.  
  5. Fit the boot into the groove in the cylinder bore and press in the set ring.
  6.  
  7. On FS17, install the main pin boots to the torque plate. Install the sub pin slide bushing into the torque plate.
  8.  
  9. On PD60, install the collar and dust boots into the caliper. Make sure they are firmly secured to the groove in the caliper. Install the bushing into the boots so that it is firmly set in the boot groove.
  10.  
  11. Install the caliper and brake pads.
  12.  
  13. Install the wheels and lower the truck. Bleed the brakes and road test the vehicle.
  14.  



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Fig. Fig. 1: Remove the dust boot



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Fig. Fig. 2: On 4 piston calipers, fabricate a piece of wood



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Fig. Fig. 3: Force the pistons out of their bores with compressed air



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Fig. Fig. 4: Seat the piston in the caliper bore



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Fig. Fig. 5: Exploded view of the front disc brake-1975-83 2WD Pick-Up (exc. Cab and Chassis) w/S16-type caliper



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Fig. Fig. 6: Exploded view of the front disc brake-1975-83 2WD Pick-Up (Cab and Chassis) w/K-type caliper



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Fig. Fig. 7: Exploded view of the front disc brake-1975-87 4WD Pick-up and 4Runner and 1975-88 Land Cruiser



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Fig. Fig. 8: Exploded view of the front disc brake-1988 4WD Pick-up and 4Runner



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Fig. Fig. 9: Exploded view of the front disc brake-1984-88 2WD Pick-up w/FS17 type caliper



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Fig. Fig. 10: Exploded view of the front disc brake-1984-88 2WD Pick-up w/PD60 type caliper



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Fig. Fig. 11: Force the pistons out of their bores with compressed air



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Fig. Fig. 12: Install the piston seal and then press the piston into the caliper bore



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Fig. Fig. 13: Removing the piston with compressed air



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Fig. Fig. 14: Removing the piston from the caliper



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Fig. Fig. 15: Removing the dust seal from the caliper



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Fig. Fig. 16: Removing the O-ring seal from the caliper

 
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