FRONT BRAKE (for 4WD and Pre-Runner) REASSEMBLY

Tech Tips


  • Use the same procedures for the LH side and RH side.

  • The procedures listed below are for the LH side.


  1. INSTALL FRONT DISC

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    1. Align the matchmarks and install the disc.

      Tech Tips

      When replacing the disc with a new one, select the installation position where the disc has the smallest runout.

  2. CHECK DISC RUNOUT

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    1. Check the bearing play in the axial direction and the axle hub runout Click here.

    2. Temporarily install the disc with the 6 hub nuts.

    3. Using a dial indicator, measure the disc runout 10 mm (0.394 in.) from the outer edge of the disc.

      Maximum disc runout
      0.05 mm (0.00197 in.)

      If the runout is greater than the maximum even when the installation position is changed, grind the disc.

      Standard thickness
      Item Specified Condition
      for 15 inch Front Disc Brake 25.0 mm (0.984 in.)
      for 16 inch Front Disc Brake 28.0 mm (1.102 in.)
      Minimum thickness
      Item Specified Condition
      for 15 inch Front Disc Brake 23.0 mm (0.906 in.)
      for 16 inch Front Disc Brake 26.0 mm (1.024 in.)

      If the disc thickness is less than the minimum, replace the disc.

    4. Remove the hub nuts and disc.

  3. TEMPORARILY INSTALL FRONT DISC BRAKE BLEEDER PLUG


    1. Temporarily install the bleeder plug to the cylinder.

      Tech Tips

      The bleeder plug will be tightened to the torque specification in the "bleed air from brake line" procedures.

    2. Install the cap to the bleeder plug.

  4. INSTALL PISTON SEAL


    1. Apply lithium soap base glycol grease to 4 new seals.

    2. Install the 4 seals to the cylinder.

      Note

      Do not forcibly install the seals to the cylinder.

  5. INSTALL FRONT DISC BRAKE PISTON

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    1. Apply lithium soap base glycol grease to the 4 pistons and 4 new cylinder boots.

    2. Install the 4 boots to the pistons.

    3. Install the 4 pistons (with the boots) to the cylinder.

      Note

      Do not forcibly install the pistons to the cylinder.

  6. INSTALL CYLINDER BOOT

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    1. Install the boots into the grooves of the cylinder and pistons.

      Note

      Make sure that the boots are securely installed into the grooves of the cylinder and pistons.

    2. Install the 4 new set rings.