Rebuild front brake calipers by disassembling, cleaning, replacing seals and boots, and reassembling calipers to restore proper brake function.

Warnings

Tools required

Parts

• Front brake caliper rebuild kit (seals, boots, hardware) × 2 — Use OEM Toyota specification
• DOT 3 brake fluid × 1 — Use OEM specification
• Brake cleaner spray × 1 — Non-chlorinated brake parts cleaner

Fluids

• DOT 3 Brake Fluid — 0.5 qt

Preparation

1. Park vehicle on level surface, engage parking brake, and place wheel chocks behind rear wheels
2. Loosen front wheel lug nuts while vehicle is on ground
3. Raise front of vehicle with jack and secure on jack stands rated for vehicle weight
4. Remove front wheels completely
5. Verify you have complete rebuild kits for both front calipers before beginning disassembly
6. Set up clean workspace with lint-free towels for caliper disassembly
7. Have new brake fluid ready - do NOT reuse old fluid
8. Open brake fluid reservoir and use turkey baster or syringe to remove old fluid to minimum line

Procedure

1. 1

   Remove caliper from vehicle
   Place drain pan under caliper. Using line wrench, disconnect brake line fitting from caliper (10mm). Immediately plug line with rubber cap to prevent fluid loss and contamination. Remove caliper slide pin bolts (17mm) and lift caliper off bracket. Support caliper and remove from vehicle. Cap caliper ports to prevent contamination.
   ⚠Brake fluid will drain from line. Have drain pan positioned and plug line immediately.
   Torque spec

   Line Fittings20 Nm (15 lb-ft)

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)
2. 2

   Disassemble caliper body
   Work in clean area with lint-free towels. Remove dust boot retaining ring if present. Carefully pry out dust boot. Place wooden block or several shop towels inside caliper opening. Using compressed air at LOW PRESSURE (30-40 PSI max) applied to brake line port, gently blow piston out of caliper bore. DO NOT place fingers in front of piston. Remove piston seal from caliper bore groove using plastic pick - do not scratch bore surface.
   ⚠️Piston will eject with force. Keep fingers clear and use wooden block to catch piston. High air pressure can cause piston to become a projectile.
   ⚠Never use metal tools on caliper bore. Any scratches will cause seal failure and brake fluid leaks.
3. 3

   Clean and inspect caliper components
   Thoroughly clean caliper bore, piston, and all internal passages with brake parts cleaner. Inspect caliper bore for scoring, pitting, or corrosion. Inspect piston for chrome plating damage, scoring, or corrosion. Any damage to bore or piston requires caliper replacement - do not attempt to rebuild damaged calipers. Clean bleeder screw threads and verify it moves freely. Dry all components with compressed air and lint-free towels.
   ⚠If caliper bore or piston shows ANY scoring, pitting, or corrosion, replace the entire caliper. Damaged surfaces will cause immediate seal failure.
4. 4

   Install new piston seal
   Lubricate new piston seal from rebuild kit with clean DOT 3 brake fluid. Carefully install seal into caliper bore groove using fingers only - ensure seal seats completely in groove without twisting. Verify seal is properly seated around entire circumference.
   ℹ️Only use clean brake fluid for lubrication. Never use petroleum-based products which will destroy rubber seals.
5. 5

   Install piston and dust boot
   Lubricate piston and caliper bore with clean DOT 3 brake fluid. Carefully insert piston into bore, ensuring it does not catch or damage the seal. Push piston fully into bore - it should slide smoothly. Install new dust boot into piston groove first, then stretch boot over caliper body and seat into caliper groove. Install retaining ring if equipped. Verify boot is properly seated with no twists or gaps.
6. 6

   Service slide pins and brackets
   Remove slide pins from caliper bracket. Clean slide pins and bracket bores thoroughly with brake cleaner. Inspect pins for corrosion, scoring, or damage. Inspect rubber boots for tears or damage. Replace boots if damaged. Apply thin coat of high-temp silicone brake grease to slide pins and reinstall into bracket with new boots from rebuild kit. Verify pins move smoothly in bracket.
7. 7

   Install rebuilt caliper to bracket
   Apply medium-strength thread locker to slide pin bolt threads. Position rebuilt caliper onto bracket, aligning with slide pins. Install and hand-tighten slide pin bolts. Torque slide pin bolts to specification using torque wrench.
   ℹ️Apply silicone brake grease to slide pins before caliper installation as specified in torque database.
   Torque spec

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)
8. 8

   Connect brake line
   Remove plugs from brake line and caliper port. Verify threads are clean and undamaged. Thread brake line fitting into caliper by hand to avoid cross-threading. Using line wrench, torque brake line fitting to specification. Do not overtighten - this can damage the fitting and cause leaks.
   ⚠Cross-threaded brake line fittings require replacement of caliper and/or line. Thread by hand first to ensure proper engagement.
   Torque spec

   Line Fittings20 Nm (15 lb-ft)
9. 9

   Bleed brake caliper
   Attach clear tubing to bleeder screw and place other end in container with small amount of clean brake fluid. Have assistant pump brake pedal 3-4 times and hold pressure. Open bleeder screw 1/4 turn while pedal is held down - fluid and air will flow out. Close bleeder screw before pedal reaches floor. Repeat until fluid flows with no air bubbles. Torque bleeder screw to specification. Top off brake fluid reservoir between bleeding cycles. Never let reservoir run dry.
   ⚠️If brake pedal goes to floor or reservoir runs dry during bleeding, air enters master cylinder requiring complete system bleed. Never let reservoir go below minimum line.
   ⚠Do not overtighten bleeder screw - specified torque is only 10 Nm. Overtightening will strip threads or break bleeder.
   Torque spec

   Bleeder Screw10 Nm (7 lb-ft)
10. 10

    Repeat process for second caliper
    Repeat steps 1-9 for the opposite front caliper. Work methodically and maintain clean workspace. After both calipers are rebuilt and bled, perform final system bleeding starting from right rear, left rear, right front, then left front wheel.
11. 11

    Reinstall wheels and perform final checks
    Install wheels and hand-tighten lug nuts in star pattern. Lower vehicle until wheels just contact ground. Torque lug nuts to specification in star pattern using torque wrench. Fully lower vehicle and remove jack stands. Verify brake fluid reservoir is at MAX line with clean DOT 3 fluid. Pump brake pedal repeatedly until firm - pedal should be high and firm, not spongy.
    ⚠️Do NOT drive vehicle until brake pedal is firm and high. Spongy or low pedal indicates air in system requiring additional bleeding.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Ensure all brake line fittings are properly torqued with line wrench
2. Verify caliper slide pins move freely and are properly greased
3. Confirm brake fluid reservoir is at MAX line with fresh DOT 3 fluid
4. Check for any brake fluid leaks at caliper body and line fittings
5. Verify dust boots are properly seated with no tears or gaps

Verification

• With vehicle safely supported, have assistant press brake pedal while you inspect each caliper for leaks at piston seals and line fittings
• Brake pedal must be firm and high - if pedal is spongy or goes to floor, repeat bleeding procedure
• Perform test drive in safe area at low speed (under 10 mph) to verify brakes engage smoothly without pulling to either side
• After test drive, inspect calipers again for any signs of fluid leakage
• Perform several moderate stops from 30-40 mph in safe area to verify proper brake function and seat pads
• Recheck brake fluid level after test drive - top off if needed
• Monitor brake performance over next 100 miles and recheck fluid level - any drop in fluid indicates leak requiring immediate attention

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