Front Brake: Installation: Installation

1. Align the matchmarks of the disc and axle hub, and install the disc.
   Fig 1: Identifying Matchmarks On Disc And Axle Hub

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   When replacing the disc with a new one, select the installation position where the front disc has the minimal runout.

1. Install the disc brake cylinder mounting to the steering knuckle with the 2 bolts.
   Fig 2: Locating Front Disc Brake Cylinder Mounting Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: 107 N*m (1089 kgf*cm, 79 ft.*lbf) 

1. Apply a light layer of lithium soap base glycol grease to the entire circumference of 2 new front disc brake bushing dust boots.
   Fig 3: Apply Lithium Soap Base Glycol Grease To Rear Disc Brake Bush Dust Boots

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT: 

   Apply at least 0.3 g (0.01 oz.) of lithium soap base glycol grease to each front disc brake bushing dust boot.

2. Install the 2 front disc brake bushing dust boots to the disc brake cylinder mounting.
   Fig 4: Identifying Front Disc Brake Bushing Dust Boots

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply a light layer of lithium soap base glycol grease to the contact surface of the No. 2 front disc brake cylinder slide pin.
   Fig 5: Identifying Lithium Soap Base Glycol Grease Applying Area

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install a new front disc brake cylinder slide bushing to the No. 2 front disc brake cylinder slide pin.

1. Apply a light layer of lithium soap base glycol grease to the sliding and sealing surfaces of the No. 1 front disc brake cylinder slide pin and No. 2 front disc brake cylinder slide pin.
   Fig 6: Identifying No. 1 and No. 2 Front Disc Brake Cylinder Slide Pins

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the No. 1 front disc brake cylinder slide pin and No. 2 front disc brake cylinder slide pin to the cylinder mounting.
   Fig 7: Identifying Front Disc Brake Cylinder Slide Pin

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the 2 No. 1 front disc brake pad support plates and 2 No. 2 front disc brake pad support plates to the front disc brake cylinder mounting.
   Fig 8: Identifying Front Disc Brake Pad Support Plate

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   Be sure to install each front disc brake pad support plate in the correct position and direction.

1. Apply disc brake grease to both sides of each No. 1 anti-squeal shim.
   Fig 9: Identifying No. 1 & No. 2 Anti-Squeal Shims

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   • When replacing worn pads, the anti-squeal shims must be replaced together with the pads.
   • Install the shims in the correct positions and directions.
   • Apply disc brake grease to the area that contacts the anti-squeal shims.
   • Disc brake grease can seep out slightly from the area where the anti-squeal shim is installed.
   • Make sure that disc brake grease is not applied onto the lining surface.
2. Install the No. 1 anti-squeal shim and No. 2 anti-squeal shim to each brake pad.

1. Install the 2 disc brake pads to the disc brake cylinder mounting.
   Fig 10: Identifying Front Disc Brake Pad

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   There should be no oil or grease on the friction surfaces of the disc brake pads or the front disc.

1. Hold the front disc brake cylinder slide pin and install the disc brake cylinder assembly to the disc brake cylinder mounting with the 2 bolts.
   Fig 11: Removing/Installing Bolts And Disc Brake Cylinder Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: 34 N*m (347 kgf*cm, 25 ft.*lbf) 

1. Connect the front flexible hose to the disc brake cylinder assembly with the union bolt and a new gasket.
   Fig 12: Locating Front Flexible Hose Union Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) 

   HINT: 

   Install the flexible hose lock securely into the lock hole in the disc brake cylinder.

Torque: 103 N*m (1050 kgf*cm, 76 ft.*lbf)