How to service and repair the brake caliper on 2002 Toyota 4Runner?

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The first step to serve or fix the brake caliper begins with wheel removal followed by disc fixation using hub nuts at 103 Nm torque. Use Special Service Tool: 09023-00100 to disconnect the brake line while wearing a brake fluid collection container because of a 15 Nm torque specification (155 kgf-cm, 11 ft. lbs). The removal of the caliper starts with unscrewing 2 mounting bolts torqued to 123 Nm (1,250 kgf-cm, 90 ft. lbs.) then continuing with clip removal together with 2 pins, anti-rattle spring and 2 pads and their corresponding 4 anti-squeal shims. The task requires a screwdriver to extract the 4 cylinder boot set rings and boots before constructing a wooden plate to support the pistons between them with a pad installed on one side while cleaning the pistons with compressed air starting from one end while avoiding finger placement in front of the pistons. A screwdriver will help extract the 4 piston seals which need to be removed from the cylinder. The pad lining thickness should be measured with a ruler to determine if it reaches the standard 11.5 mm (0.453 inch) or if it must be replaced due to a minimum requirement of 1.0 mm (0.039 inch); any pad showing sign of uneven wear needs immediate replacement. The measurement process involves a micrometer to check disc thickness against the standard 22.0mm (0.866inch) and minimum 20.0mm (0.787inch). Disc replacement must happen if the measurement reaches or falls under the minimum or reveals scoring and uneven wear. Start by measuring disc runout with a dial indicator at 10 mm (0.39 inch) from the edge to check if it remains below 0.07 mm (0.0028 inch); proceed to replace either the disc or conduct grinding on a "On-Car" brake lathe before front hub bearing play measurement. To achieve proper disc runout installation, users should start by unscrewing the hub nuts and removing the disc before reinstalling it with one-sixth turn adjustment from its previous position. Users should then retighten the hub nuts to 103 Nm (1,050 kgf-cm, 76 ft. lbs.) followed by repeat runout measurement until the disc reaches its best fit position with minimum runout lower than maximum values. Users should replace the disc in cases where the readings cannot achieve these conditions. Lithium soap base glycol grease gets applied first followed by a reverse installation process of disassembly. Bleeding of the brake system should follow fluid addition into the brake reservoir along with inspections for system leaks.

OEM 2002 Toyota 4Runner Brake Caliper

4 Brake Calipers found

2002 Toyota 4Runner Caliper, Driver Side

2002 Toyota 4Runner Caliper, Passenger Side

2002 Toyota 4Runner Caliper, Driver Side

2002 Toyota 4Runner Caliper, Passenger Side

2002 Toyota 4Runner Brake Caliper

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