FRONT BRAKE (for TSAM Made 2WD) INSTALLATION

Tech Tips


  • Use the same procedure for the RH and LH sides.

  • The procedure listed below is for the LH side.


  1. INSTALL FRONT DISC


    1. A01E21TE01

      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 minimum runout.

  2. INSTALL FRONT DISC BRAKE BUSH DUST BOOT


    1. A01DXP2E03

      Apply a light coat of lithium soap base glycol grease to 2 new boots.

    2. Install the 2 boots to the mounting.

  3. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN


    1. A01DXQEE02

      Apply a light coat of lithium soap base glycol grease to the pins and a new bush as shown in the illustration.

    2. Install the bush to the pin (lower).

    3. Install the 2 pins (upper and lower) to the mounting.

  4. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING LH


    1. Install the cylinder mounting with the 2 bolts.

      Torque:
      117 N*m  { 1191 kgf*cm, 86 ft.*lbf }

  5. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE


    1. Install the 2 plates to the mounting.

  6. INSTALL FRONT ANTI-SQUEAL SHIM KIT


    1. A01E1SGE03

      Install the No. 1 and No. 2 anti-squeal shims to each pad as shown in the illustration.

      Note

      There should be no oil or grease on the friction surface of the pads and disc.

  7. INSTALL FRONT DISC BRAKE PAD


    1. Install the 2 disc brake pads to the mounting.

      Note

      There should be no oil or grease on the friction surface of the pads and disc.

  8. INSTALL DISC BRAKE CYLINDER ASSEMBLY LH


    1. A01DZD0E02

      Apply silicon grease on contact surface of each fingers.

    2. A01E2ZF

      Install the cylinder with the 2 bolts.

      Torque:
      29 N*m  { 291 kgf*cm, 21 ft.*lbf }

  9. CONNECT FRONT FLEXIBLE HOSE


    1. A01DV73

      Connect the flexible hose with a new gasket and new union bolt.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

      Note

      Install the flexible hose lock securely in the lock hole in the cylinder.

  10. FILL RESERVOIR WITH BRAKE FLUID

    Fluid
    SAE J1704 or FMVSS No. 116 DOT 4

  11. BLEED AIR FROM BRAKE MASTER CYLINDER

    Tech Tips

    If the master cylinder has been disassembled or if the reservoir becomes empty, bleed air from the master cylinder.


    1. Using a union nut wrench, disconnect the 2 brake lines from the master cylinder.

      A01E24CE01

    2. Slowly depress and hold the brake pedal.

    3. Cover the outer holes with your finger, and release the pedal.

      A01DV4BE01

    4. Repeat the 2 previous steps 3 or 4 times.

    5. Using a union nut wrench, connect the 2 brake lines to the master cylinder.

      Torque:
      15 N*m  { 155 kgf*cm, 11 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

  12. BLEED AIR FROM BRAKE LINE


    1. Remove the bleeder plug cap.

    2. Connect the vinyl tube to the bleeder plugs.

    3. Depress the pedal several times, and then loosen the bleeder plug with the pedal depressed.

    4. When fluid stops coming out, immediately tighten the bleeder plug. Then release the pedal.

    5. Repeat the 2 previous steps until all the air in the brake fluid is gone.

    6. Tighten the bleeder plug.

      Torque:
      for front brake (2WD)
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      for front brake (4WD and Pre-Runner)
      11 N*m  { 110 kgf*cm, 8 ft.*lbf }
      for rear brake (2WD)
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }
      for rear brake (4WD and Pre-Runner)
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    7. Install the cap.

    8. Bleed air from the brake line for each wheel by repeating the above procedures.

  13. BLEED AIR FROM CLUTCH LINE (for Manual Transmission)

    A01E1RYE01

    1. Remove the bleeder plug cap.

    2. Connect the vinyl tube to the bleeder plug.

    3. Depress the clutch pedal several times, and then loosen the bleeder plug with the pedal depressed.

    4. At the point when fluid stops coming out, tighten the bleeder plug, and then release the clutch pedal.

    5. Repeat the previous 2 steps until all the air in the fluid is completely bled out.

    6. Tighten the bleeder plug.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

    7. Install the bleeder plug cap.

    8. Check that all the air has been bled out of the clutch line.

  14. CHECK BRAKE FLUID LEVEL IN RESERVOIR


    1. A01DVQK

      Check the fluid level.

      If the brake fluid level is lower than the MIN line, check for leaks and inspect the disc brake pads. If necessary, refill the reservoir with brake fluid to the MAX line after repair or replacement.

      Fluid
      SAE J1704 or FMVSS No. 116 DOT 4

  15. CHECK FOR BRAKE FLUID LEAKAGE

  16. INSTALL FRONT WHEEL


    1. Install the front wheel.

      Torque:
      for steel wheel
      152 N*m  { 1550 kgf*cm, 112 ft.*lbf }
      for aluminum wheel
      121 N*m  { 1234 kgf*cm, 89 ft.*lbf }