OEM 2003 Toyota Prius Brake Caliper

2003 Toyota Prius Parts Questions & Experts Answers

• Q: How to service and repair the brake caliper on 2003 Toyota Prius?

  A: The brake caliper servicing process starts with unscrewing both the set ring and cylinder boot through the use of a screwdriver. After positioning a cloth between the caliper and piston you can extract the piston with compressed air while avoiding placing fingers before the piston's location. User a screwdriver to remove the piston seal before taking out the sequence of sliding pins from the torque plate together with the removal of the 2 dust boots. The standard pad lining thickness should be 11.0 mm (0.433 inch) and the minimum should be 1.0 mm (0.039 inch) for a proper inspection. Therefore, replace the pad if the thickness measurement reveals equality or decrease or if it exhibits serious uneven wear. A micrometer should measure disc thickness because the standard stands at 22.0 mm (0.866 inch) but the minimum is set at 20.0 mm (0.787 inch); disc replacement must occur with any thickness reaching the minimum limit or when scoring or uneven wear becomes unbearable. A dial indicator enables the measurement of disc runout at 10 mm (0.39 inch) from the outer edge and the maximum allowable runout measurement stands at 0.05 mm (0.0020 inch). When this value is surpassed, verify bearing axial play and axle hub runout before disc assessment for adjustment or grinding. Proceed with disc adjustment by removing the 2 bolts with torque plate from the knuckle before you can take out the hub nuts and disc. Install the disc at a 1/4 turned position relative to its initial hub placement while tightening the hub nuts to 103 Nm (1,050 kgf-cm, 76 ft. lbs.). Measure disc runout after finishing disc installation at the ideal position and record runout results and disc placement. Repeat this procedure until you find the most optimal disc sitting. The preferred disc position for installation will be the one that shows a minimum runout less than 0.05 mm (0.0020 inch); otherwise replace the disc and perform the runout check again. Complete the installation by putting on the torque plate then tighten the mounting bolts to 107 Nm (1,090 kgf-cm, 79 ft. lbs.). Reassembly requires the use of lithium soap base glycol grease which should be applied to noted components as the process goes backward from disassembly.