Replace both rear brake rotors on a 2019-2024 Toyota RAV4 2.5L I4 FWD, including caliper removal, rotor replacement, and proper torque specifications.

Warnings

Tools required

Parts

• Rear brake rotor × 2 — Use OEM or quality aftermarket (43512-42080 or equivalent)
• Rotor set screws (if corroded) × 2 — 90116-04083 or equivalent

Preparation

1. Park vehicle on level, solid surface and engage parking brake firmly
2. Place wheel chocks in front of both front wheels
3. Open hood and remove master cylinder reservoir cap to allow fluid displacement when compressing pistons (do not allow fluid to overflow)
4. Loosen rear wheel lug nuts 1/4 turn while vehicle is on ground
5. Lift rear of vehicle with floor jack at designated rear jacking point
6. Place jack stands under rear subframe or chassis jacking points per owner's manual
7. Lower vehicle onto jack stands and ensure stability before working
8. Remove rear wheels completely and set aside

Procedure

1. 1

   Inspect brake system and prepare caliper
   Visually inspect brake pads, calipers, and brake hoses for damage, leaks, or excessive wear. Check brake fluid level in master cylinder reservoir. Prepare a wire hanger or bungee cord to support the caliper once removed.
2. 2

   Remove caliper slide pin bolts
   Locate the two caliper slide pin bolts on the rear of the caliper assembly. Using a 17mm socket or wrench, remove both caliper slide pin bolts. Keep these bolts clean and inspect for damage or excessive wear.
   ⚠Do not allow caliper to hang by brake hose after removal. Support it immediately with wire or bungee cord.
   Torque spec

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)
3. 3

   Support and secure caliper
   Carefully pivot the caliper up and off the rotor. Immediately support the caliper using wire or bungee cord hung from the suspension or chassis. Ensure no tension is placed on the rubber brake hose. Do not disconnect the brake line.
4. 4

   Remove caliper bracket
   Using a 14mm socket or wrench, remove the two caliper bracket bolts that secure the bracket to the hub/spindle assembly. These bolts are typically very tight. Remove the caliper bracket completely and set aside with the brake pads still attached (or remove pads for inspection).
   ⚠Caliper bracket bolts are high-torque fasteners. Ensure proper socket engagement to avoid rounding bolt heads.
   Torque spec

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

   Remove rotor set screws and rotor
   Using a Phillips head screwdriver, remove the rotor set screw(s) securing the rotor to the hub (usually one or two screws). These may be corroded and difficult to remove; apply penetrating oil if needed. Once set screws are removed, pull the rotor straight off the hub. If rotor is stuck, use a dead blow hammer or rubber mallet to tap it from behind to break it free from the hub.
   ℹ️Corroded set screws may strip easily. Use proper-fitting screwdriver and consider replacing if damaged.
   Torque spec

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

   Clean hub surface and prepare new rotor
   Thoroughly clean the hub mounting surface with a wire brush to remove rust, debris, and corrosion. The surface must be clean and flat for proper rotor seating. Clean the new rotor thoroughly with brake parts cleaner to remove protective oil coating from both friction surfaces and the hat section. Wipe dry with clean, lint-free cloth.
   ⚠Oil or grease on rotor friction surfaces will contaminate brake pads and cause brake failure. Ensure rotors are completely clean.
7. 7

   Install new rotor
   Apply a thin layer of anti-seize compound to the hub pilot diameter (not the rotor friction surfaces). Place the new rotor onto the hub, aligning the screw holes. Install rotor set screw(s) and tighten to specification. The rotor should sit flush against the hub with no wobble or gaps.
   Torque spec

   Rotor Set Screws7 Nm (5 lb-ft)
8. 8

   Compress caliper piston
   Before reinstalling the caliper bracket, the caliper piston must be compressed fully into its bore to accommodate the new rotor thickness. Use a C-clamp or brake caliper piston tool against the back of the piston (or old brake pad) to slowly compress the piston. Watch the master cylinder reservoir and ensure fluid does not overflow; remove fluid with turkey baster if needed.
   ⚠Compress piston slowly to avoid damaging internal caliper seals or forcing air into ABS system.
9. 9

   Reinstall caliper bracket
   Position the caliper bracket back onto the hub/spindle mounting surface. Install both caliper bracket bolts and tighten to specification using torque wrench. Ensure bracket is seated properly before final torque.
   Torque spec

   Caliper Bracket Bolts102 Nm (75 lb-ft)
10. 10

    Reinstall caliper assembly
    Remove caliper from its support wire/bungee. Inspect caliper slide pins for damage and ensure they move freely; apply silicone brake grease to slide pins if needed. Position caliper over the rotor and bracket, aligning slide pin bolt holes. Install both caliper slide pin bolts and tighten to specification.
    Torque spec

    Caliper Slide Pin Bolts35 Nm (26 lb-ft)
11. 11

    Repeat process for opposite side
    Perform all previous steps (steps 1-10) on the opposite rear wheel to replace the second rear rotor. Ensure both sides are completed to the same standard and all fasteners are properly torqued.
12. 12

    Reinstall wheels and lower vehicle
    Reinstall both rear wheels, starting lug nuts by hand. Tighten lug nuts in a star/cross pattern with torque wrench to specification. Raise vehicle slightly with floor jack, remove jack stands, and lower vehicle completely to ground. Perform final lug nut torque check in star pattern with vehicle on ground.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Reinstall master cylinder reservoir cap securely
2. Press brake pedal slowly several times until firm pedal is achieved (this seats brake pads against new rotors)
3. Check master cylinder fluid level and top off with DOT 3 brake fluid if needed
4. Do not drive vehicle until firm brake pedal is confirmed

Verification

• Pump brake pedal until firm resistance is felt; pedal should not sink to floor
• Check for brake fluid leaks around calipers and brake hoses
• Verify all lug nuts are torqued to specification in star pattern
• Perform low-speed brake test in safe area to confirm brakes engage properly before normal driving
• During first 100-200 miles, avoid hard braking to allow proper rotor and pad break-in bedding process
• Listen for abnormal noises during brake application; properly installed rotors should be silent except for initial break-in noise
• Re-check lug nut torque after first 50 miles of driving

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