This procedure replaces a single rear brake rotor on a 2019-2024 Toyota RAV4 with the 2.5L I4 gas engine, including caliper removal, rotor replacement, and proper torque specifications.

Warnings

Tools required

Parts

• Rear brake rotor × 1 — Use OEM Toyota or equivalent quality aftermarket
• Rotor set screw (if corroded) × 1 — 90116-05005 or equivalent M5 screw

Preparation

1. Park vehicle on level surface and engage parking brake
2. Loosen rear wheel lug nuts 1/4 turn while vehicle is on the ground
3. Raise rear of vehicle with floor jack and support securely on jack stands under manufacturer-specified jacking points
4. Remove rear wheel completely
5. Verify you are working on the correct rear wheel (left or right) for the rotor being replaced
6. Inspect brake fluid level in master cylinder reservoir; if low, top off with DOT 3 brake fluid before compressing caliper piston

Procedure

1. 1

   Remove caliper slide pin bolts
   Locate the two caliper slide pin bolts on the rear of the caliper assembly. Using a 14mm socket, remove both slide pin bolts completely. Keep these bolts as they will be reused. Note any grease present on the pins for reassembly.
   Torque spec

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

   Remove and support brake caliper
   Carefully lift the caliper off the rotor and brake pads. Do not let the caliper hang by the brake hose. Use wire or a bungee cord to securely hang the caliper from the suspension spring or strut. Ensure there is no tension on the rubber brake hose.
   ⚠️Never allow caliper to hang unsupported by the brake hose. Hose damage can cause catastrophic brake failure.
3. 3

   Remove brake pads
   Remove both brake pads from the caliper bracket. Note their orientation and the location of any anti-rattle clips or shims. Set pads aside in a clean area if reusing, or discard if replacing with new pads.
   ℹ️If replacing only the rotor and not the pads, inspect pad thickness. Pads less than 3mm thick should be replaced.
4. 4

   Remove caliper bracket
   Using a 17mm socket, remove the two caliper bracket bolts that secure the bracket to the steering knuckle. These bolts are torqued to a high specification. The bracket will then lift off the rotor. Keep these bolts as they will be reused.
   Torque spec

   Caliper Bracket Bolts102 Nm (75 lb-ft)
5. 5

   Remove rotor set screw
   Locate the Phillips rotor set screw on the face of the rotor (through one of the wheel stud holes). Remove this screw using a Phillips screwdriver. If corroded, use penetrating oil and an impact driver. This screw is often damaged during removal and should be replaced.
   ℹ️The set screw is for assembly purposes and prevents rotor from falling during manufacturing. It can be omitted if severely corroded, though replacement is preferred.
   Torque spec

   Rotor Set Screws7 Nm (5 lb-ft)
6. 6

   Remove old brake rotor
   Pull the rotor straight off the hub. If the rotor is stuck due to corrosion, tap the rotor from behind with a rubber mallet or dead blow hammer in the area between the wheel studs. Alternate tapping around the rotor to break it free evenly. Do not strike the rotor friction surface or wheel studs.
   ⚠Rusted rotors may require significant force. Use penetrating oil and allow time to soak if extremely stuck.
7. 7

   Clean hub surface
   Clean the hub mounting surface thoroughly with a wire brush to remove rust, corrosion, and debris. The hub surface must be clean and flat for proper rotor seating. Wipe clean with brake cleaner and a lint-free cloth. Inspect wheel studs for damage.
   ℹ️An uneven hub surface will cause rotor runout, leading to pedal pulsation and uneven wear.
8. 8

   Prepare and install new rotor
   Remove protective coating from new rotor using brake cleaner and lint-free cloths. Clean both friction surfaces thoroughly. Slide the new rotor onto the hub, aligning the rotor holes with the wheel studs. Ensure the rotor sits flush against the hub surface with no gaps.
   ℹ️Failure to remove protective coating will cause noise, poor braking, and contamination during initial use.
9. 9

   Install rotor set screw
   Install the rotor set screw (new or cleaned original) through one of the wheel stud holes and thread into the hub. Torque to specification using a torque wrench. This holds the rotor in place during reassembly.
   Torque spec

   Rotor Set Screws7 Nm (5 lb-ft)
10. 10

    Compress brake caliper piston
    Using a C-clamp or brake caliper piston tool, slowly compress the caliper piston fully into the caliper bore. Place the tool against the back of the piston (inside the caliper) and compress evenly. Monitor the brake fluid reservoir to ensure it does not overflow as the piston retracts.
    ⚠Brake fluid may overflow from reservoir during piston compression. Remove excess fluid with a turkey baster or syringe if necessary to prevent spills on paint.
11. 11

    Reinstall caliper bracket
    Position the caliper bracket over the rotor and align the mounting holes with the steering knuckle. Install both caliper bracket bolts and hand-tighten. Using a torque wrench and 17mm socket, torque both bracket bolts to specification in an alternating pattern.
    Torque spec

    Caliper Bracket Bolts102 Nm (75 lb-ft)
12. 12

    Reinstall brake pads
    Install the brake pads into the caliper bracket in their correct positions with the friction material facing the rotor. Ensure any anti-rattle clips or shims are properly positioned as noted during disassembly. Pads should fit snugly but slide freely in the bracket.
13. 13

    Reinstall brake caliper
    Remove the caliper from its supported position. Apply a thin layer of silicone brake grease to the slide pin shafts (the smooth portion that slides, not the threads). Position the caliper over the brake pads and align the slide pin bolt holes. Insert both slide pin bolts and hand-tighten.
    ℹ️Use only silicone brake grease on slide pins. Other greases can deteriorate rubber components or fail at brake operating temperatures.
    Torque spec

    Caliper Slide Pin Bolts35 Nm (26 lb-ft)
14. 14

    Torque caliper slide pin bolts
    Using a torque wrench and 14mm socket, torque both caliper slide pin bolts to specification. Verify both bolts are properly torqued. Ensure the caliper moves freely on the slide pins by pushing on it gently.
    Torque spec

    Caliper Slide Pin Bolts35 Nm (26 lb-ft)
15. 15

    Reinstall wheel and torque lug nuts
    Reinstall the rear wheel, threading lug nuts by hand to prevent cross-threading. Using a torque wrench and 21mm socket, torque all lug nuts to specification in a star pattern. Lower vehicle from jack stands until tire just touches ground, then perform final torque verification in star pattern with vehicle weight on wheel.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Double-check all fasteners are torqued to specification
2. Verify brake caliper slide pins move freely and are properly greased
3. Ensure brake caliper and bracket are securely mounted with no movement
4. Confirm rotor is properly seated on hub with no wobble or runout

Verification

• Before starting vehicle, pump brake pedal several times until firm pedal feel is achieved. Pedal should not go to floor.
• Check brake fluid level in master cylinder reservoir and top off with DOT 3 fluid if needed
• Perform a low-speed brake test (5-10 mph) in a safe area to verify proper brake function before normal driving
• Expect some noise and reduced braking effectiveness for the first 50-100 miles during rotor and pad break-in period
• Monitor for any vibration, noise, or pulling during braking. Any abnormalities require immediate inspection
• After 50-100 miles, re-torque wheel lug nuts to specification to ensure they have not loosened
• If replacing only one rear rotor, monitor for any brake pull to one side, which may indicate the need to replace both rear rotors for balanced braking

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