This procedure covers disassembly, cleaning, inspection, seal replacement, and reassembly of the rear brake calipers on a 2019-2024 Toyota RAV4 2.5L I4 FWD.

Warnings

Tools required

Parts

• Rear brake caliper rebuild kit (contains piston seals, dust boots, bleeder caps) × 2 — Use OEM Toyota part or equivalent
• Brake fluid DOT 3 × 1 — Toyota genuine recommended
• Caliper slide pin boot kit (if damaged) × 2 — Use OEM specification

Fluids

• DOT 3 Brake Fluid — 1 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Loosen rear wheel lug nuts while vehicle is on ground
3. Lift rear of vehicle using floor jack at approved jacking points and support securely on jack stands
4. Remove both rear wheels completely
5. Verify you have complete rebuild kits for both rear calipers before disassembly
6. Open brake fluid reservoir and check level, then place a clean rag over opening to prevent contamination
7. Have clean workspace prepared with lint-free towels and parts cleaning area

Procedure

1. 1

   Remove caliper from mounting bracket
   Remove the caliper slide pin bolts (upper and lower) using appropriate socket. Lift caliper off the rotor and pads. Support caliper with wire or bungee cord - do NOT let it hang by the brake hose. Mark left and right calipers to avoid mixing components during rebuild.
   Torque spec

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

   Disconnect brake hose
   Place drain container under caliper. Clean area around brake hose banjo bolt thoroughly. Remove banjo bolt and separate brake hose from caliper. Immediately cap or plug the brake hose end to prevent fluid loss and contamination. Discard old crush washers - new ones should be included in rebuild kit or purchased separately.
   ⚠Brake fluid will drain from hose and caliper. Catch all fluid and dispose of properly according to local regulations.
3. 3

   Remove piston from caliper body
   Move to clean workspace. If using compressed air: wrap caliper in towel, insert air nozzle into brake hose port, and apply gradually increasing air pressure (start at 20-30 PSI) until piston ejects. Keep fingers clear of piston path. Alternatively, use a caliper press or large C-clamp from the dust boot side to push piston out. Once piston starts moving, it should come out with controlled pressure.
   ⚠️Piston can eject with significant force if using compressed air. Keep hands and face clear of piston path. Use only enough pressure to move piston.
4. 4

   Remove dust boot and piston seal
   Remove the dust boot from the caliper bore groove using a pick tool, working carefully around the circumference. Remove the piston seal from its groove in the caliper bore using a plastic or wooden pick - do NOT use metal tools that could score the bore. Discard all old seals and boots.
   ⚠Do not use sharp metal tools inside the caliper bore. Scratches or gouges in the bore surface will cause seal leakage and caliper failure.
5. 5

   Clean and inspect caliper bore and piston
   Spray caliper bore thoroughly with brake parts cleaner and wipe with lint-free towels. Inspect bore for scoring, pitting, rust, or corrosion. Light surface rust can be removed with fine emery cloth or caliper hone - polish in circular motion only. Clean piston with brake parts cleaner and inspect chrome surface for pitting, scoring, or peeling. Any significant damage to bore or piston requires caliper replacement - do not attempt to rebuild.
   ⚠If caliper bore diameter has increased from wear, or if piston chrome is compromised, the caliper cannot be safely rebuilt and must be replaced.
6. 6

   Remove and inspect slide pins
   Remove both caliper slide pins from the mounting bracket by pulling out. Remove old rubber boots. Clean slide pins thoroughly with brake parts cleaner and inspect for wear, corrosion, or damage. Clean slide pin bores in bracket. Replace boots if torn, cracked, or deteriorated.
   Torque spec

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)
7. 7

   Install new piston seal
   Ensure caliper bore is completely clean and dry. Apply thin coat of fresh brake fluid to new piston seal. Carefully install seal into the groove in caliper bore using fingers or seal installation tool. Ensure seal is seated evenly in groove all the way around with no twists or pinches. Do not use sharp tools.
   ⚠Piston seal must be properly seated in its groove without twists or damage. A damaged seal will cause immediate brake failure.
8. 8

   Install piston and dust boot
   Apply thin coat of fresh brake fluid to piston outer surface and caliper bore. Install dust boot onto piston groove first (if design requires), or install into caliper bore groove first per rebuild kit instructions. Carefully start piston into bore by hand, ensuring it enters straight without cocking. Use caliper piston tool or padded C-clamp to press piston slowly into bore until it bottoms. Seat dust boot into both grooves (piston and caliper) ensuring it is not twisted or pinched.
   ⚠Piston must enter bore perfectly straight. Cross-threading or cocking the piston will damage the new seal and ruin the rebuild.
9. 9

   Lubricate and install slide pins
   Apply silicone brake grease liberally to slide pins. Install new rubber boots onto slide pin grooves and bracket bores. Insert slide pins into bracket bores and verify they move smoothly with slight resistance. Wipe away excess grease.
   Torque spec

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)
10. 10

    Install rebuilt caliper to bracket
    Ensure brake pads are properly positioned in bracket. Position rebuilt caliper over brake pads and rotor. Align caliper slide pin bolt holes with slide pins. Install and hand-tighten both slide pin bolts, then torque to specification using torque wrench. Apply silicone brake grease to slide pin bolt threads as specified.
    Torque spec

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

    Reconnect brake hose
    Clean brake hose banjo fitting and caliper port. Install NEW crush washers on both sides of banjo fitting (one against caliper, one under bolt head). Thread banjo bolt by hand to ensure proper threading, then torque to specification. Verify hose is not twisted or kinked.
    Torque spec

    Mounting Bolts27 Nm (20 lb-ft)
12. 12

    Bleed brake caliper
    Attach bleeder hose to bleeder screw and submerge other end in container with clean brake fluid. Have assistant pump brake pedal 3-4 times and hold pressure, or use vacuum bleeder. Open bleeder screw 1/2 turn and allow fluid/air to escape. Close bleeder screw before pedal reaches floor. Repeat until no air bubbles appear and only clean fluid flows. Torque bleeder screw to specification - do not overtighten.
    ⚠Bleeder screws are brass and easily damaged. Torque carefully to specification and do not exceed specified value.
    Torque spec

    Bleeder Screw10 Nm (7 lb-ft)
13. 13

    Repeat for opposite side
    Perform steps 1-12 for the opposite rear caliper. Maintain cleanliness and inspect all components carefully. Bleed the second caliper thoroughly following same procedure.
14. 14

    Install wheels and perform final bleeding
    Install wheels and hand-tighten lug nuts. Lower vehicle to ground and torque lug nuts to specification in star pattern. Top off brake fluid reservoir to MAX line with fresh DOT 3 fluid. Perform final brake bleeding starting with wheel furthest from master cylinder (right rear, left rear, right front, left front) to ensure all air is removed from system.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Ensure all caliper slide pin bolts are torqued to 35.0 Nm (26 lb-ft)
2. Verify brake hose banjo bolts are tight and using new crush washers
3. Confirm brake fluid reservoir is filled to MAX line with fresh DOT 3 fluid
4. Check that no brake fluid has contacted brake pads or rotors

Verification

• Pump brake pedal multiple times - pedal should become firm and hold pressure without sinking
• Verify no brake fluid leaks at caliper, bleeder screw, or brake hose connections
• Check that calipers move freely on slide pins when pushing vehicle by hand
• Test drive in safe area at low speed - brakes should apply smoothly and evenly without pulling to one side
• After test drive, inspect calipers for leaks and verify wheels are not excessively hot indicating dragging brakes
• Re-check brake fluid level after test drive and top off if needed
• Perform emergency stop test from 25 mph in safe location - vehicle should stop straight without pulling or vibration

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