OEM 2005 Toyota RAV4 Brake Caliper

2005 Toyota RAV4 Parts Questions & Experts Answers

• Q: How to service and repair the front brake caliper on 2005 Toyota RAV4?

  A: The front brake caliper service process begins with flexible hose disconnect through bolt removal of the union bolt and two gaskets procedure while collecting falling brake fluid in a container. Reconnect the caliper using a torque of 30 Nm (310 kgf-cm) that requires two new gaskets and proper insertion of the flexible hose into the lock hole. You should first hold the sliding pin before loosening the 2 installation bolts to 26 Nm torque (270 kgf-cm, 20 ft. lbs.) and remove both components from the torque plate. The repair process begins with screwdriver disassembly of the cylinder boot set ring and cylinder boot, after which a cloth must be inserted between the piston and caliper to use compressed air and extract the piston while safeguarding your fingers before the piston. You can disconnect the piston seal by using a screwdriver before removing the 2 sliding pins and 2 dust boots that are attached to the torque plate. As part of inspection use a ruler to measure pad lining thickness which must be at least 12.0 mm (0.472 in.) standard but should never fall below 1.0 mm (0.039 in.) since replacement is needed at either threshold or for severe uneven pad wear. Disc thickness measurement using a micrometer must be conducted and a replacement or grinding process is necessary if either minimum criterion at 23.0 mm (0.906 in.) for disc thickness or scoring or uneven disc wear conditions are present. Use a dial indicator to check disc runout at 10 mm (0.39 in.) from the edge with a 0.05 mm (0.0020 in.) maximum allowable runout limit; when the runout surpasses this value check bearing play and axle hub runout and adjust or grind the disc appropriately. Follow this sequence for hub disc adjustment: firstly remove the torque plate and 2 bolts from the knuckle then all hub nuts along with the disc, install the turned disc 1/5 from its first position before torquing the hub nuts to 103 Nm (1,050 kgf-cm, 76 ft. lbs.). Continue adjusting the disc until the minimum runout reaches values below 0.05 mm (0.0020 in.), then install this position finally or replace it if minimum runout values exceed 0.05 mm (0.0020 in.). The last step involves the installation of the torque plate where you should torque all mounting bolts to 106 Nm (1,090 kgf-cm, 78 ft. lbs.). Reassembly occurs in the opposite order of the disassembly steps and demands lithium soap base glycol grease application to designated parts prior to installation according to the reverse sequence of part removal. Finish the installation process by adding fluid to the brake reservoir then inspect brake system pressure while evaluating for any fluid leaks.