Toyota Previa 1991-1997 Repair Information

Brake Caliper

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REMOVAL & INSTALLATION



See Figures 1 through 7

  1. Disconnect the negative battery cable from the battery.
  2.  
  3. Raise and support the vehicle safely.
  4.  
  5. Remove the wheels.
  6.  
  7. Disconnect the brake hose from the caliper by removing the union bolt and two gaskets. Plug the end of the hose to prevent loss of fluid.
  8.  

Have a pan ready to catch any spilt brake fluid.

  1. Remove the bolts that attach the caliper to the torque plate.
  2.  



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Fig. Fig. 1: Remove the upper caliper mounting bolt ... .



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Fig. Fig. 2: ...then remove the bottom bolt



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Fig. Fig. 3: The lower bolt is larger than the top

  1. Lift the bottom of the caliper up and remove the caliper assembly.
  2.  



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Fig. Fig. 4: The entire caliper should slide off the disc

To install:
  1. Grease the caliper slides and bolts with lithium grease or equivalent. Install the caliper and secure with the bolts. Tighten the front caliper bolts to 27 ft. lbs. (36 Nm) and the rear to 18 ft. lbs. (25 Nm).
  2.  
  3. Reconnect the brake hose to the caliper, using two new washers. Make sure the flexible hose lock is securely in the lock hole of the caliper. Tighten the union bolt to 22 ft. lbs. (30 Nm). Also, verify that the brake hose is not twisted.
  4.  
  5. Fill the brake system to the proper level and bleed the brake system.
  6.  
  7. Install the tire and wheel assembly.
  8.  
  9. Top off the brake fluid level in the master cylinder. Check for leaks and proper brake operation.
  10.  
  11. Connect the negative battery cable to the battery.
  12.  



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Fig. Fig. 5: Two bolts hold the rear caliper



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Fig. Fig. 6: Remove bolt the bolts ...



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Fig. Fig. 7: ... then lift the rear caliper off the brake disc

OVERHAUL



See Figures 8 through 15

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.

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      Fig. Fig. 8: 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. Fig. 9: Withdraw the piston from the caliper bore

    4.  

  2.  
  3. For the second method, you must rotate the piston to retract it from the caliper.
  4.  

  1. If equipped, remove the anti-rattle clip.
  2.  



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Fig. Fig. 10: 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. Fig. 11: Use a prytool to carefully pry around the edge of the boot ...



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Fig. Fig. 12: ... 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. Fig. 13: 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. Fig. 14: 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. Fig. 15: There are tools, such as this Mighty-Vac, available to assist in proper brake system bleeding

 
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