This procedure replaces the front brake caliper on a 2019-2024 Toyota RAV4 2.5L I4 FWD, including brake fluid bleeding and system verification.

Warnings

Tools required

Parts

• Front brake caliper assembly × 1 — Use OEM specification or quality aftermarket
• Brake hose copper washers × 2 — 90430-12031 or equivalent (2 per banjo bolt)
• DOT 3 brake fluid × 1 — Use OEM specification

Fluids

• DOT 3 Brake Fluid — 0.25 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Loosen wheel lug nuts 1/4 turn while vehicle is on ground
3. Raise front of vehicle with floor jack and support on jack stands rated for vehicle weight (approximately 3,600 lbs)
4. Remove front wheel completely
5. Use turkey baster or fluid extractor to remove approximately 1/3 of brake fluid from master cylinder reservoir to prevent overflow when compressing caliper piston
6. Clean brake caliper area thoroughly with brake parts cleaner to prevent contamination during disassembly

Procedure

1. 1

   Remove caliper mounting bolts
   Using a 17mm wrench or socket, remove the two caliper slide bolts (upper and lower) that secure the caliper to the bracket. These bolts thread into the caliper slide pins. Support the caliper as you remove the second bolt to prevent it from falling.
2. 2

   Support and secure caliper
   Carefully lift the caliper off the brake rotor and brake pads. DO NOT let it hang by the brake hose. Use wire or a bungee cord to hang the caliper from the suspension spring or other secure location. Keep tension off the brake hose.
   ⚠Allowing the caliper to hang by the brake hose can cause internal hose damage leading to brake failure.
3. 3

   Disconnect brake hose from caliper
   Place a drain pan or absorbent pads beneath the connection point. Using a 10mm flare nut wrench, loosen and remove the brake hose banjo bolt from the back of the caliper. Brake fluid will spill. Immediately plug the open brake hose end with a rubber cap or wrap in plastic to prevent fluid loss and contamination. Remove and discard both copper crush washers from the banjo bolt.
   ⚠Brake fluid will drain from the hose. Have absorbent materials ready and plug the hose immediately to minimize fluid loss.
4. 4

   Remove old caliper
   Remove the caliper completely from the vehicle. Inspect the brake hose banjo fitting for damage or corrosion. If the hose shows any signs of cracking, bulging, or damage, replace it now before installing the new caliper.
   ℹ️Dispose of brake fluid-soaked materials according to local regulations. Do not pour brake fluid down drains.
5. 5

   Prepare new caliper for installation
   Remove the new caliper from packaging. Verify it matches the old caliper exactly (mounting points, bleeder position, hose connection location). If the new caliper comes with a compressed piston, verify it is fully seated. If not compressed, use a C-clamp to fully compress the piston into the caliper bore before installation.
   ℹ️Some replacement calipers come pre-lubricated. Do not remove slide pin boots or grease unless reinstalling old slide pins.
6. 6

   Connect brake hose to new caliper
   Install NEW copper crush washers on both sides of the brake hose banjo fitting (one washer against the caliper body, one washer between the banjo fitting and bolt head). Position the brake hose so it is not twisted or kinked. Thread the banjo bolt by hand first to ensure proper threading, then tighten to specification using a torque wrench.
   ⚠️Never reuse old copper washers. This can cause brake fluid leaks and complete brake failure.
7. 7

   Install caliper onto bracket
   Ensure brake pads are properly positioned in the caliper bracket. Carefully slide the new caliper over the brake rotor and pads, aligning the caliper slide pin holes with the bracket. Insert both caliper slide bolts and thread by hand initially to verify proper alignment.
8. 8

   Torque caliper mounting bolts
   Using a torque wrench, tighten both caliper slide bolts to the specified torque of 88.0 Nm (65.0 lb-ft). Tighten in a cross pattern (alternate between upper and lower) to ensure even seating.
9. 9

   Bleed brake caliper
   Attach a clear hose to the bleeder screw on the back of the caliper and place the other end in a container partially filled with clean brake fluid. Have an assistant pump the brake pedal 3-4 times and hold pressure. Open the bleeder screw 1/4 turn using a 10mm wrench. Fluid and air will flow out. Close the bleeder before the pedal reaches the floor. Repeat until no air bubbles appear in the hose (typically 5-10 cycles). Check master cylinder level frequently and top off with fresh DOT 3 fluid - never let it run dry.
   ⚠️If the master cylinder runs dry, air will enter the ABS system requiring professional scan tool bleeding. Monitor fluid level constantly.
   Torque spec

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

    Final bleeder screw torque
    After bleeding is complete and no air bubbles remain, with an assistant holding brake pedal pressure, close the bleeder screw and torque to 10.0 Nm (7.0 lb-ft). Remove the bleed hose and wipe away any spilled brake fluid with a clean rag.
    ⚠Do not overtighten the bleeder screw - it can strip or break, making future bleeding impossible without caliper replacement.
    Torque spec

    Bleeder Screw10 Nm (7 lb-ft)
11. 11

    Reinstall wheel and lower vehicle
    Clean the wheel hub face and reinstall the wheel. Thread lug nuts by hand initially to prevent cross-threading. Snug lug nuts in a star pattern with the lug wrench, then lower vehicle until tire contacts ground but weight is not fully transferred.
12. 12

    Final torque wheel lug nuts
    With vehicle weight on the ground, torque all lug nuts to 136.0 Nm (100.0 lb-ft) in a star pattern using a torque wrench. Fully lower vehicle and remove jack stands.

Reassembly

1. Top off brake master cylinder reservoir to MAX line with fresh DOT 3 brake fluid
2. Verify brake hose is not twisted, kinked, or making contact with suspension components through full steering range
3. Pump brake pedal firmly 10-15 times to seat caliper piston against new pads - pedal should feel firm
4. Check all brake line connections for leaks while assistant applies firm pedal pressure

Verification

• Start engine and verify brake warning light is OFF on instrument cluster
• Press brake pedal firmly - it should feel solid with no sponginess. If pedal is soft or sinks, air remains in system and further bleeding is required
• Inspect all brake line connections for fluid seepage while applying firm brake pedal pressure for 30 seconds
• Perform a low-speed brake test in a safe area (5-10 mph) to verify proper brake function before driving at normal speeds
• After initial test drive (first 20-30 miles), re-check brake fluid level and inspect caliper/brake hose connections for any signs of leakage
• CRITICAL: Perform a controlled stop from 25-30 mph in a safe area before returning to normal driving. Braking should be smooth and straight with no pulling to either side
• If any abnormal behavior occurs (pulling, grinding, soft pedal, warning lights), DO NOT DRIVE - have vehicle towed to a professional technician

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