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Home >> Scion >> 2005 >> tC L4-2.4L (2AZ-FE) >> Repair and Diagnosis >> Brakes and Traction Control >> Disc Brake System >> Service and Repair >> Front

Front






FRONT BRAKE
OVERHAUL

HINT:
- Use the same procedures for the RH side and LH side.
- The procedures listed are for the LH side.

1. REMOVE FRONT WHEEL
2. DRAIN BRAKE FLUID

NOTICE: Wash brake fluid off immediately if it adheres to any painted surface.





3. REMOVE DISC BRAKE CYLINDER ASSEMBLY LH
a. Remove the union bolt and gasket from the disc brake cylinder assembly, then disconnect the flexible hose.
b. Remove the 2 bolts and disc brake cylinder assembly.
4. REMOVE FRONT DISC BRAKE PAD KIT
a. Remove the 2 brake pads w/ antisqueal shims.
5. REMOVE ANTI SQUEAL SHIM KIT FRONT
a. Remove the 4 anti-squeal shims from each pad.
b. Remove the pad wear indicator plate from the inner pad.
6. REMOVE FRONT DISC BRAKE PAD SUPPORT PLATE
a. Remove the pad support plate (No.1) from the cylinder mounting LH.
7. REMOVE FRONT DISC BRAKE PAD SUPPORT PLATE
a. Remove the pad support plate (No.2) from the cylinder mounting LH.
8. REMOVE FRONT DISC BRAKE CYLINDER SLIDE PIN
a. Remove the 2 cylinder slide pins from the cylinder mounting LH.
9. REMOVE FRONT DISC BRAKE BUSH DUST BOOT
a. Remove the 2 bush dust boots from the cylinder mounting LH.
10. REMOVE FRONT DISC BRAKE CYLINDER MOUNTING LH
a. Remove the 2 bolts and cylinder mounting LH.





11. REMOVE CYLINDER BOOT
a. Using a screwdriver, remove the set ring and cylinder boot.





12. REMOVE FRONT DISC BRAKE PISTON
a. Place a piece of shop rag or equivalent between the piston and the disc brake cylinder assembly.
b. Use compressed air to remove the piston from the disc brake cylinder assembly.

CAUTION: Do not place your fingers in front of the piston when using compressed air.

NOTICE: Do not scatter brake fluid.

13. REMOVE PISTON SEAL
a. Using a screwdriver, remove the piston seal from the disc brake cylinder assembly.

NOTICE: Do not damage the inner cylinder and cylinder groove.

14. REMOVE FRONT DISC BRAKE BLEEDER PLUG
15. INSPECT BRAKE CYLINDER AND PISTON
a. Check the cylinder bore and piston for rust or scoring.
If necessary, replace the disc brake cylinder assembly or piston.





16. INSPECT PAD LINING THICKNESS
a. Using a ruler, measure the pad lining thickness.
Standard thickness: 11.5 mm (0.453 inch)
Minimum thickness: 1.0 mm (0.039 inch)
If the pad lining thickness is equal to the minimum thickness or less, replace the brake pad kit front.
17. INSPECT FRONT DISC BRAKE PAD SUPPORT PLATE
a. Make sure that both plates have sufficient rebound, have no deformation, cracks or wear, and that all rust and dirt are cleaned off.
If necessary, replace the brake pad support plate (No.1).
18. INSPECT FRONT DISC BRAKE PAD SUPPORT PLATE
a. Make sure that both plates have sufficient rebound, have no deformation, cracks or wear, and that all rust and dirt are cleaned off.
If necessary, replace the brake pad support plate (No.2).





19. INSPECT DISC THICKNESS
a. Using a micrometer, measure the disc thickness.
Standard thickness: 25.0 mm (0.984 inch)
Minimum thickness: 23.0 mm (0.906 inch)
If the disc thickness is less than the minimum, replace the disc.





20. REMOVE FRONT DISC
a. Put matchmarks on the disc and the axle hub.
b. Remove the front disc.
21. INSTALL FRONT DISC
a. Aligning the matchmarks, install the front disc.

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





22. INSPECT DISC RUNOUT
a. Check the bearing play in the axial direction and check for the axle hub runout.
b. Temporarily fasten the front disc together with the hub nuts.
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
c. Using a dial indicator, measure the disc runout 10 mm (0.39 inch) away from the outer edge of the front disc.
Maximum disc runout: 0.05 mm (0.0020 inch)
If the runout exceeds the maximum value, change the installation positions of the disc and axle so that the runout will become minimal. If the runout exceeds the maximum even when the installation positions are changed, grind the disc. If the disc thickness is less than the minimum. replace the front disc.
23. TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG
24. INSTALL PISTON SEAL
a. Apply lithium soap base glycol grease to a new piston seal.
b. Install the piston seal to the disc brake cylinder assembly.





25. INSTALL FRONT DISC BRAKE PISTON
a. Apply lithium soap base glycol grease to the piston and a new cylinder boot.
b. Install the cylinder boot to the piston.
c. Install the piston to the disc brake cylinder assembly.

NOTICE: Do not install the piston forcibly in the cylinder assembly.





26. INSTALL CYLINDER BOOT
a. Install the cylinder boot to the disc brake cylinder assembly.

HINT: Install the boot securely to the grooves of the cylinder and piston.

b. Using a screwdriver, install a new set ring.

NOTICE:
- Install the boot securely to the grooves of the cylinder and piston.
- Do not damage the lavender boot.

27. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING LH
a. Install the cylinder mounting LH with the 2 bolts.
Torque: 107 Nm (1,090 kgf-cm, 79 ft. lbs.)





28. INSTALL FRONT DISC BRAKE BUSH DUST BOOT
a. Apply lithium soap base glycol grease to seal surface of 2 new bush dust boots.
b. Install the 2 bush dust boots to the cylinder mounting LH.





29. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN
a. Apply lithium soap base glycol grease to the sliding part and the seal surface of the 2 cylinder slide pins.
b. Install the 2 cylinder slide pins to the cylinder mounting LH.
30. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE
a. Install the pad support plate (No.1) to the cylinder mounting LH.
31. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE
a. Install the pad support plate (No.2) to the cylinder mounting LH.





32. INSTALL ANTI SQUEAL SHIM KIT FRONT
a. Apply disc brake grease to the inside of the 2 antisqueal shims and install them.
b. Install the 2 outside antisqueal shims to the brake pads.

NOTICE: When replacing worn pads, the antisqueal shims must be replaced together with the brake pads.

c. Install the pad wear indicator plate to the inner pad.

NOTICE: Install the pad wear indicator plate in the correct position and direction.

33. INSTALL FRONT DISC BRAKE PAD KIT
a. Install the inner pad w/ pad wear indicator plate facing upward, and install the outer pad.

NOTICE: There should be no oil or grease on the friction surface of the pads and the disc.

34. INSTALL DISC BRAKE CYLINDER ASSEMBLY LH
a. Install the front disc brake cylinder assembly with the 2 bolts.
Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.)
b. Connect the flexible hose with the union bolt and a new gasket.
Torque: 30 Nm (310 kgf-cm, 22 ft. lbs.)

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

35. FILL RESERVOIR WITH BRAKE FLUID
36. BLEED MASTER CYLINDER
SST 09023-00101
37. BLEED BRAKE LINE
38. CHECK FLUID LEVEL IN RESERVOIR
39. CHECK FOR BRAKE FLUID LEAKAGE
40. INSTALL FRONT WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)



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