OEM 2003 Toyota RAV4 Brake Caliper

2003 Toyota RAV4 Parts Questions & Experts Answers

• Q: How to service and repair the brake caliper on 2003 Toyota RAV4?

  A: Start by using a screwdriver to take off the cylinder boot set ring together with the cylinder boot for brake caliper service and repair work. Harbor a piece of cloth between the piston and caliper before you push out the piston through compressed air but ensure your fingers remain behind the piston at all times. Start by using a screwdriver to remove the piston seal followed by the removal of two sliding pins from the torque plate together with the two dust boots. The pad lining thickness needs to be measured using a ruler before replacing the pads under the following conditions: a minimum of 1.0 mm (0.039 inch) thickness and severe uneven wear or the pad lining measurement reaches or falls below the standard 12.0 mm (0.472 inch), or shows extreme wear. A micrometer check of 25.0 mm (0.984 inch) must be within the standard or it should be replaced or both the standard and minimum of 23.0 mm (0.906 inch) are not met before replacement if the disc exhibits scoring or uneven wear. A dial indicator must measure disc runout at a 10 mm (0.39 inch) point from the edge to check if runout remains below 0.05 mm (0.0020 inch); further checks should be made on the bearing play and axle hub runout before disc adjustment or grinding takes place. To make adjustments start by taking off the two bolts and torque plate from the knuckle followed by disc and hub nut removal then replace the disc with the hub placement rotated one-fifth position from its initial position before torquing hub nuts to 103 Nm (1,050 kgf-cm, 76 ft. lbs.). After each adjustment verifies the disc runout and check the disc position and execute adjustments until the minimum runout achieves less than 0.05 mm (0.0020 inch) or replace the disc if the runout is greater than this minimum value. The last step involves using a torque plate while mounting bolts are tightened to 106 Nm (1,090 kgf-cm) torque value (78 ft. lbs.). Starting from step one, reassembly requires lithium soap base glycol grease on notified parts before proceeding through the steps in reverse order of disassembly.