Toyota Pick-ups/Land Cruiser/4Runner 1989-1996

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

2WD Vehicles
  1. Elevate and safely support the vehicle.
  2.  
  3. Remove the wheel.
  4.  
  5. Disconnect the brake line from the caliper.
  6.  
  7. Remove the bolts holding the caliper to the torque plate.
  8.  
  9. Remove the caliper from the torque plate.
  10.  
  11. Remove the pads and shims.
  12.  

To install:
  1. Install the pads and shims.
  2.  
  3. Fit the caliper into position. Install the two retaining or slide bolts, then tighten to:

    FS-17 or 18 brakes-65 ft. lbs. (88 Nm)
     
    PD 60 or 66 brakes-29 ft. lbs. (39 Nm)
     
    T100 1 / 2 ton-27 ft. lbs. (36 Nm)
     
    T100 1 ton-29 ft. lbs. (39 Nm)
     

  4.  
  5. Install the brake line, tightening the fitting to 11-22 ft. lbs. (15-30 Nm).
  6.  
  7. Install the wheel.
  8.  
  9. Lower the vehicle to the ground. Bleed the brakes and road test the vehicle.
  10.  

4WD Vehicles

See Figures 1, 2 and 3

  1. Raise the front of the truck, support it on jackstands, and remove the front wheel.
  2.  
  3. Plug the vent hole on the master cylinder cap to prevent fluid leak. Loosen the brake line from the caliper, being careful not to deform the fittings.
  4.  



Click image to see an enlarged view

Fig. Fig. 1: With a line wrench, loosen the brake line from the caliper

  1. Remove the 2 caliper mounting bolts, and remove the caliper.
  2.  



Click image to see an enlarged view

Fig. Fig. 2: Remove the upper and lower mounting bolts



Click image to see an enlarged view

Fig. Fig. 3: Slide the caliper assembly off of the rotor

  1. Pull out the two wire clips at the ends of the pad pins.
  2.  
  3. Pull out the pads and anti-rattle spring.
  4.  
  5. Remove the brake pads, and the anti-squeal shims.
  6.  

To install:
  1. Position the caliper and install the mounting bolts. Tighten the caliper mounting bolts to 90 ft. lbs. (123 Nm). Be certain to position the shims correctly.
  2.  
  3. Connect the brake line to the caliper. On all models except 1991-96 Land Cruisers, tighten the line fitting to 11 ft. lbs. (15 Nm). For 1991-96 Land Cruisers, tighten it to 22 ft. lbs. (30 Nm).
  4.  
  5. Install the brake pads.
  6.  
  7. Install the wheel and lower the truck. Bleed the brakes and road test the vehicle.
  8.  

OVERHAUL



2WD Vehicles
  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 bushings, pin dust boots 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.  


CAUTION
Keep fingers away from the front of the piston during removal. Injury may occur when the piston comes out.

  1. Remove the piston seal from the caliper cylinder bore. Check the piston and cylinder bore for wear and/or corrosion. Replace components as necessary.
  2.  

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 types, install the main pin boots to the torque plate. Install the sub pin slide bushing into the torque plate.
  8.  
  9. On PD60 types, 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.  

4WD Vehicles

See Figures 4, 5 and 6

  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 rings out of the caliper. Remove the dust boots.
  6.  



Click image to see an enlarged view

Fig. Fig. 4: Using a seal pick, remove the dust boot rings

  1. Insert a piece of wood about 1 / 2 in. thick between the caliper pistons.
  2.  



Click image to see an enlarged view

Fig. Fig. 5: Place a piece of wood between the pistons, then apply compressed air to force them out

  1. Apply compressed air to the brake line union to force the piston out of its bore. Be careful; the piston will come out forcefully.
  2.  


CAUTION
Keep fingers away from the front of the piston during removal. Injury may occur when the piston comes out.

  1. Remove the piston seals from the caliper cylinder bores. Check each piston and cylinder bore for wear and/or corrosion. Replace components as necessary.
  2.  



Click image to see an enlarged view

Fig. Fig. 6: Once the pistons are removed, use the seal pick to withdraw the piston seals


WARNING
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 based glycol grease.
  2.  
  3. Install the piston seals then the pistons into the caliper cylinder bores. Seat the pistons in the bores with your fingers.
  4.  
  5. Fit the boots into the grooves in the cylinder bores and press in the set rings.
  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.  

 
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