Toyota Pick-ups, Land Cruiser, and 4 Runner 1997-00

Brake Caliper

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REMOVAL & INSTALLATION



2WD Vehicles


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Fig. To remove the brake hose, unthread the banjo bolt from the caliper

  1. Elevate and safely support the vehicle.
  2.  
  3. Remove the wheel.
  4.  
  5. If removing the caliper from the vehicle for overhaul or replacement, disconnect the brake line from the caliper, then plug the line and port. If not, it is not necessary to disconnect the fluid line.
  6.  
  7. Remove the bolts holding the caliper to the torque plate.
  8.  
  9. Remove the caliper from the torque plate. If not replacing or overhauling the caliper, suspend it from a suspension component with a piece of wire. NEVER let the caliper hang by the brake hose.
  10.  
  11. If necessary, remove the pads and shims.
  12.  

To install:

  1. If removed, install the pads and shims.
  2.  
  3. Fit the caliper into position. Install the two retaining or slide bolts, then tighten as follows:

    FS17 or 18 brakes: 65 ft. lbs. (88 Nm)
     
    PD60 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 1122 ft. lbs. (1530 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


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Fig. Exploded view of the front brake caliper assembly



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Fig. Use a closed-end wrench to remove the banjo bolt from the brake hose



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Fig. Close up view of a brake hose banjo bolt



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Fig. Remove the hydraulic brake line from the caliper



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Fig. The caliper is secured with two mounting bolts

  1. Raise the front of the truck, support it on jackstands, and remove the front wheel.
  2.  
  3. If removing the caliper for replacement or overhaul, unfasten the union bolt and two gaskets from the caliper, then disconnect the brake fluid hoses from the caliper, being careful not to deform the fittings. If you are not replacing the caliper, and just removing it for rotor or other component replacement, it is not necessary to disconnect the brake fluid line.
  4.  
  5. Unfasten the two caliper mounting bolts, then remove the caliper from the rotor. If you are not replacing the caliper, you can suspend it out of the way with a suitable piece of wire.
  6.  
  7. If necessary, remove the following:
    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.  

  8.  

To install:

  1. If removed, install the brake pads.
  2.  
  3. Position the caliper over the rotor and install the mounting bolts. Tighten the caliper mounting bolts to 90 ft. lbs. (123 Nm). Be certain to position the shims correctly.
  4.  

Make sure to install the flexible brake hose lock securely in the lock hole in the caliper.

  1. If disconnected, attach the brake line to the caliper. Tighten the union bolt to 22 ft. lbs. (30 Nm).
  2.  
  3. Install the wheel and lower the truck. Bleed the brakes and road test the vehicle.
  4.  

OVERHAUL



Some vehicles may be equipped dual piston calipers. The procedure to overhaul the caliper is essentially the same with the exception of multiple pistons, O-rings and dust boots.

  1. Remove the caliper from the vehicle and place on a clean workbench.
  2.  


CAUTION
NEVER place your fingers in front of the pistons in an attempt to catch or protect the pistons when applying compressed air. This could result in personal injury!

Depending upon the vehicle, there are two different ways to remove the piston from the caliper. Refer to the brake pad replacement procedure to make sure you have the correct procedure for your vehicle.

  1. The first method is as follows:
    1. Stuff a shop towel or a block of wood into the caliper to catch the piston.
    2.  
    3. Remove the caliper piston using compressed air applied into the caliper inlet hole. Inspect the piston for scoring, nicks, corrosion and/or worn or damaged chrome plating. The piston must be replaced if any of these conditions are found.
    4.  

  2.  



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Fig. For some types of calipers, use compressed air to drive the piston out of the caliper, but make sure to keep your fingers clear



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Fig. Withdraw the piston from the caliper bore

  1. For the second method, you must rotate the piston to retract it from the caliper.
  2.  
  3. If equipped, remove the anti-rattle clip.
  4.  



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Fig. On some vehicles, you must remove the anti-rattle clip

  1. Use a prytool to remove the caliper boot, being careful not to scratch the housing bore.
  2.  



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Fig. Use a prytool to carefully pry around the edge of the boot . . .



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Fig. . . . then remove the boot from the caliper housing, taking care not to score or damage the bore

  1. Remove the piston seals from the groove in the caliper bore.
  2.  



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Fig. Use extreme caution when removing the piston seal; DO NOT scratch the caliper bore

  1. Carefully loosen the brake bleeder valve cap and valve from the caliper housing.
  2.  
  3. Inspect the caliper bores, pistons and mounting threads for scoring or excessive wear.
  4.  
  5. Use crocus cloth to polish out light corrosion from the piston and bore.
  6.  
  7. Clean all parts with denatured alcohol and dry with compressed air.
  8.  

To assemble:

  1. Lubricate and install the bleeder valve and cap.
  2.  
  3. Install the new seals into the caliper bore grooves, making sure they are not twisted.
  4.  
  5. Lubricate the piston bore.
  6.  
  7. Install the pistons and boots into the bores of the calipers and push to the bottom of the bores.
  8.  
  9. Use a suitable driving tool to seat the boots in the housing.
  10.  



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Fig. Use the proper size driving tool and a mallet to properly seal the boots in the caliper housing

  1. Install the caliper in the vehicle.
  2.  
  3. Install the wheel and tire assembly, then carefully lower the vehicle.
  4.  
  5. Properly bleed the brake system.
  6.  



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Fig. There are tools, such as this Mighty-Vac, available to assist in proper brake system bleeding

 
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