Toyota Prius 2002-06

Brake Caliper

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Removal & Installation





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Fig. Exploded view of front disc brake assembly components-2004-06 Prius

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Set brake control OFF , if necessary.
  4.  
  5. Raise and safely support the front of the vehicle.
  6.  
  7. Remove the front wheel.
  8.  
  9. Remove the bolt and the gasket attaching the brake hose to the caliper.
  10.  
  11. Disconnect the brake hose, and plug the openings in the caliper and the brake hose to prevent fluid loss and contamination.
  12.  
  13. Hold the front disc brake cylinder slide pin using a wrench.
  14.  
  15. Remove the 2 caliper mounting bolts and remove the caliper from the vehicle.
  16.  
  17. Remove the 2 disc brake pads from the front disc brake cylinder mounting.
  18.  
  19. Remove the anti-squeal shims from the disc brake pads.
  20.  
  21. Remove the front disc brake pad support plates.
  22.  
  23. Remove the slide pins and bush dust boots from the front disc brake cylinder mounting, if necessary.
  24.  
  25. Remove the front disc brake cylinder mounting from the steering knuckle, if necessary.
  26.  

To install:

  1. Install the front disc brake cylinder mounting to the steering knuckle, if removed. Torque the 2 mounting bolts to 79 ft. lbs (107 Nm) on 2002-03 models, or 81 ft. lbs. (109 Nm) on 2004-06 models.
  2.  
  3. Install new bush dust boots and slide pins into the front disc brake cylinder mounting, if necessary. Apply lithium soap base glycol grease to the sealing, sliding and fitting areas before installation.
  4.  
  5. Install the front disc brake pad support plates.
  6.  
  7. Install the anti-squeal shims onto the disc brake pads.
  8.  
  9. Install the disc brake pads onto the front disc brake cylinder mounting.
  10.  
  11. Install the brake caliper onto the mounting along with the 2 caliper mounting bolts. Torque the 2 mounting bolts to 25 ft. lbs (34 Nm).
  12.  
  13. Connect the brake hose to the caliper with bolt and a new gasket. Tighten the caliper brake hose bolt to 24 ft. lbs. (33 Nm).
  14.  
  15. Install the wheel.
  16.  
  17. Lower the vehicle.
  18.  
  19. Fill the master cylinder to the proper level with clean brake fluid.
  20.  
  21. Bleed the air out of the brake system.
  22.  
  23. Recheck the fluid level.
  24.  
  25. Repeatedly press the brake pedal to bring the pads in contact with the rotor.
  26.  

 
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