Front Brake (For 2Wd) Installation

Align the matchmarks and install the disc.

HINT:

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

Install the disc brake cylinder mounting with the 2 bolts.

Torque:

117 N*m{1193 kgf*cm, 86 ft.*lbf}

Install the 4 pad support plates to the cylinder mounting.

Install the pad wear indicator plate to the inner lower side of the pad.

Apply a light coat of disc brake grease to both sides of each No. 1 anti-squeal shim.

Install the No. 1 anti-squeal shims and No. 2 anti-squeal shims to the pads.

NOTICE:

1. When replacing a worn pad, the shims must be replaced together with the pads.
   
2. Install the shims in the correct positions and directions as shown in the illustration.
   

Install the 2 disc brake pads to the cylinder mounting.

NOTICE:

Make sure there is no oil or grease on the friction surfaces of the pads and disc.

Apply a light coat of lithium soap base glycol grease to the No. 1 collar.

Install the No. 1 collar to the disc brake cylinder assembly.

Apply a light coat of lithium soap base glycol grease to the No. 2 collar.

Install the No. 2 collar to the disc brake cylinder assembly.

Apply a light coat of lithium soap base glycol grease to the entire circumference of 4 new front disc brake bush dust boots where they contact the disc brake cylinder, and the entire inner circumference of both ends of the boots.

HINT:

Apply at least 0.3 g (0.01 oz.) of lithium soap base glycol grease to the front disc brake bush dust boot.

NOTICE:

Apply a sufficient amount of lithium soap base glycol grease to the entire circumference of the front disc brake bush dust boot and disc brake cylinder contact surfaces.

Install the 4 front disc brake bush dust boots to the disc brake cylinder assembly.

Apply a light coat of lithium soap base glycol grease to the No. 1 cylinder slide bush.

Install the No. 1 cylinder slide bush to the disc brake cylinder assembly.

Apply a light coat of lithium soap base glycol grease to the No. 2 cylinder slide bush.

Install the No. 2 cylinder slide bush to the disc brake cylinder assembly.

Install the disc brake cylinder with the 2 bolts.

Torque:

39 N*m{400 kgf*cm, 29 ft.*lbf}

Install a new gasket and connect the flexible hose with a new union bolt.

Torque:

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

HINT:

Insert the flexible hose lock securely into the lock hole in the cylinder.

Remove the brake master cylinder reservoir filler cap assembly.

Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.

Fluid:

SAE J1703 or FMVSS No. 116 DOT 3

Remove the bleeder plug cap.

Connect a vinyl tube to the bleeder plug.

Depress the brake pedal several times, and then loosen the bleeder plug with the pedal depressed.*1

When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal.*2

Repeat *1 and *2 until all air in the fluid is completely bled out.

Tighten the bleeder plug completely.

Torque:

for Front Brake:

11 N*m{110 kgf*cm, 8 ft.*lbf}

for Rear Brake (for 4WD and Pre-Runner):

10 N*m{102 kgf*cm, 7 ft.*lbf}

for Rear Brake (for 2WD):

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

Install the bleeder plug cap.

Repeat the above procedure for each wheel to bleed the brake line.

Check for brake fluid leaks.

Check the brake fluid level in the reservoir (HILUX_TGN26 RM0000010K400VX.html).

Remove the bleeder plug cap of the release cylinder.

Connect a vinyl tube to the bleeder plug.

Depress the clutch pedal several times, and then loosen the bleeder plug while the pedal is depressed.

When fluid no longer comes out, tighten the bleeder plug, and then release the clutch pedal.

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

Tighten the bleeder plug.

Torque:

11 N*m{110 kgf*cm, 8 ft.*lbf}

Install the bleeder plug cap.

Check that all the air has been bled from the clutch line.