This procedure covers the removal and replacement of the rear brake caliper on a 2019-2024 Toyota RAV4 with the 2.5L I4 engine, including brake fluid bleeding.

Warnings

Tools required

Parts

• Rear brake caliper assembly × 1 — Use OEM specification or quality aftermarket
• Brake fluid banjo bolt copper washers × 2 — 90430-A0006 or equivalent
• DOT 3 brake fluid × 1 — Use Toyota genuine or DOT 3 specification

Fluids

• DOT 3 Brake Fluid — 0.5 qt

Preparation

1. Park vehicle on level ground and engage parking brake firmly
2. Loosen rear wheel lug nuts while vehicle is on the ground, but do not remove
3. Raise rear of vehicle with floor jack and secure on jack stands rated for vehicle weight at proper jacking points
4. Remove rear wheel completely
5. Remove approximately 1/3 of brake fluid from master cylinder reservoir using turkey baster or fluid pump to prevent overflow when compressing caliper piston
6. Inspect brake hose for cracks, bulges, or damage - replace if any defects found
7. Have all tools, new parts, and fresh brake fluid ready before disconnecting brake lines

Procedure

1. 1

   Access and support the caliper
   Locate the rear brake caliper. Before removing any bolts, prepare to support the caliper weight. If you plan to reuse the caliper (for pad replacement only), support it with wire or bungee cord to prevent hanging by the brake hose. For caliper replacement, you will disconnect the brake line so support is temporary.
2. 2

   Disconnect the brake hose from caliper
   Locate the brake hose banjo bolt connection at the rear of the caliper. Place a drain pan beneath the connection point. Using a 12mm flare nut wrench or banjo bolt wrench, loosen and remove the banjo bolt. Immediately plug the brake hose end with a rubber cap or clean lint-free rag to minimize fluid loss and prevent contamination. Remove and discard both copper crush washers from the banjo fitting - these must be replaced with new washers.
   ⚠Brake fluid will drain from both the hose and caliper. Have drain pan ready and minimize spills on painted surfaces.
3. 3

   Remove caliper mounting bolts
   Using a 17mm socket or wrench, remove the two caliper mounting bolts (also called slide pin bolts or caliper bolts) that secure the caliper to the bracket. These bolts are located on the inboard side of the caliper. The caliper will now be free. Carefully remove the caliper from the rotor and bracket assembly. Inspect the brake pads and shims - note their orientation if reusing.
   ℹ️Caliper mounting bolts may be tight. Ensure socket is fully seated to avoid rounding bolt heads.
4. 4

   Remove caliper bracket (if replacing)
   If replacing the entire caliper assembly or servicing the bracket, remove the two caliper bracket bolts using a 17mm socket. These bolts secure the bracket to the rear knuckle and require significant torque. Remove the bracket from the knuckle. Clean the bracket mounting surface on the knuckle with brake cleaner. Inspect the bracket bolt threads and apply medium-strength threadlocker to bolt threads before reinstallation if recommended.
   ℹ️Bracket bolts are very tight (100 Nm). Use a breaker bar if necessary and ensure wrench is properly seated.
   Torque spec

   Caliper Bracket Bolts100 Nm (74 lb-ft)
5. 5

   Prepare the new caliper
   Remove the new caliper from packaging. Verify the caliper piston is fully retracted. If not, carefully compress the piston using a C-clamp or brake piston tool - ensure piston goes in straight without cocking. Remove any protective caps or plugs from the brake hose port on the new caliper. Verify the bleeder screw moves freely (loosen 1/4 turn then retighten) - this confirms it is not seized.
   ℹ️Some new calipers come with brake pads pre-installed. Verify compatibility with your rotor and brake system specifications.
6. 6

   Install caliper bracket (if removed)
   Position the caliper bracket onto the rear knuckle mounting surface. Install the two bracket bolts and hand-tighten. Using a torque wrench and 17mm socket, torque the bracket bolts to specification in a cross pattern. Verify the bracket is seated flush against the knuckle.
   Torque spec

   Caliper Bracket Bolts100 Nm (74 lb-ft)
7. 7

   Install brake pads and caliper
   If brake pads were removed, install the inner and outer brake pads into the caliper bracket with anti-rattle shims in correct orientation. Apply a thin coating of high-temperature brake grease to pad slide points on bracket (not on friction surfaces). Position the new caliper over the brake rotor and pads, aligning the caliper mounting bolt holes with the bracket slide pins.
8. 8

   Install and torque caliper mounting bolts
   Insert the two caliper mounting bolts through the caliper into the bracket slide pins. Hand-thread both bolts first to ensure proper alignment. Using a torque wrench and 17mm socket, torque both caliper mounting bolts to specification. Verify the caliper moves freely on the slide pins.
9. 9

   Connect brake hose to caliper
   Install one NEW copper crush washer onto the banjo fitting of the brake hose. Position the banjo fitting into the port on the caliper with the hose properly routed (not twisted or kinked). Install the second NEW copper washer onto the banjo bolt from the opposite side. Thread the banjo bolt through the washers and into the caliper port. Hand-tighten first, then torque to specification using a torque wrench. Verify the brake hose has clearance and will not contact suspension components through full wheel travel.
   ⚠Never reuse old copper crush washers. Failure to use new washers will result in brake fluid leaks and potential brake system failure.
10. 10

    Bleed the rear brake caliper
    Attach clear brake bleeding tubing to the bleeder screw on the caliper. Submerge the other end in a clear container partially filled with fresh DOT 3 brake fluid. Have an assistant pump the brake pedal 5-6 times and hold pressure. Open the bleeder screw 1/2 turn while assistant maintains pedal pressure - fluid and air will flow into the tube. Close the bleeder screw before the pedal reaches the floor. Repeat this process until no air bubbles appear in the tubing and only clean fluid flows. Monitor the master cylinder reservoir constantly and refill as needed - never let it run dry. Torque the bleeder screw to specification.
    ⚠️If the master cylinder reservoir runs empty during bleeding, air will enter the system requiring complete brake system bleeding. Check fluid level after every 2-3 bleeder cycles.
    ⚠The bleeder screw is brass and easily damaged. Do not exceed torque specification or it may strip or break.
    Torque spec

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

    Final brake system check
    Top off the brake fluid reservoir to the MAX line with fresh DOT 3 brake fluid. Wipe all components clean of brake fluid. Inspect all connections for leaks. Pump the brake pedal repeatedly (engine off) until firm resistance is felt - the pedal should not go to the floor. If pedal remains soft, repeat bleeding process.
    ⚠️A soft or spongy brake pedal indicates air in the system. Do not drive the vehicle until a firm pedal is achieved.
12. 12

    Reinstall wheel and test
    Reinstall the rear wheel onto the hub. Install all lug nuts and hand-tighten in a star pattern. Lower the vehicle until the tire just contacts the ground (wheel cannot spin). Using a torque wrench, torque all lug nuts to specification in a star pattern. Fully lower the vehicle and remove jack stands.

Reassembly

1. Ensure all brake line connections are tight and show no signs of leakage
2. Verify brake fluid level in master cylinder reservoir is at MAX line
3. Confirm brake pedal is firm and does not sink slowly to floor when held under pressure
4. Double-check all torque specifications have been met, especially caliper bolts and wheel lug nuts

Verification

• With engine off, pump brake pedal 10-15 times - pedal should feel firm and consistent. First pump may be slightly soft but should firm up quickly
• Start engine (power brake assist active) and verify pedal height is normal and firm
• Inspect all brake connections for fluid leaks while assistant applies firm brake pressure for 30 seconds
• Check brake fluid level in reservoir - should be at MAX line
• Perform a low-speed test drive in a safe area: test brakes at 5-10 mph to verify proper operation and no pulling to one side
• After test drive, re-inspect all connections for leaks and verify brake fluid level has not dropped
• Verify wheel lug nuts are properly torqued after first 50-100 miles of driving
• CRITICAL: If brake pedal feels soft, spongy, or travels too far, or if vehicle pulls to one side during braking, DO NOT DRIVE - repeat bleeding procedure or seek professional service immediately

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