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Home >> Toyota >> 2005 >> Sienna AWD V6-3.3L (3MZ-FE) >> Repair and Diagnosis >> Brakes and Traction Control >> Disc Brake System >> Service and Repair >> Front

Front






FRONT BRAKE
OVERHAUL

HINT: Overhaul the RH side by the same procedure as the LH side.

1. REMOVE FRONT WHEEL
2. DRAIN BRAKE FLUID

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





3. REMOVE FRONT DISC BRAKE CYLINDER SUB-ASSEMBLY
a. Remove the union bolt and 2 gaskets from the front disc brake cylinder sub-assembly, then disconnect the flexible hose.
b. Hold the front disc brake cylinder slide pin and remove the 2 bolts.
4. REMOVE DISC BRAKE PAD KIT FRONT (PAD ONLY)
a. Remove the disc brake pad kit front from the front disc brake cylinder mounting LH.
5. REMOVE ANTI SQUEAL SHIM KIT FRONT
a. Remove the anti squeal shim and pad wear indicator plate from the each pad.
6. REMOVE FRONT DISC BRAKE PAD SUPPORT PLATE
a. Remove the front disc brake pad support plate (No.1) and front disc brake pad support plate (No.2) from the front disc brake cylinder mounting LH.





7. REMOVE FRONT DISC BRAKE CYLINDER SLIDE PIN
a. Remove the front disc brake cylinder slide pin (No. 1) and front disc brake cylinder slide pin (No.2) from the front disc brake cylinder mounting LH.





8. REMOVE FRONT DISC BRAKE CYLINDER SLIDE BUSH
a. Using a screwdriver, remove the front disc brake cylinder slide bush from the front disc brake cylinder slide pin (No.2)

NOTICE: Do not damage the front disc brake cylinder slide pin (No.2).





9. REMOVE FRONT DISC BRAKE CYLINDER MOUNTING LH
a. Remove the 2 bolts and front disc brake cylinder mounting LH.





10. REMOVE FRONT DISC BRAKE BUSH DUST BOOT
a. Using soft jaws on the vise, hold the front disc brake cylinder mounting LH in the vise through aluminum plates.
b. Using a screwdriver and hammer, remove the 2 front disc brake bush dust boots from the front disc brake 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 shop rug, between the front disc brake piston and the disc brake cylinder sub-assembly.
b. Use compressed air to remove the front disc brake piston from the disc brake cylinder sub-assembly.

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

NOTICE: Do not spatter the brake fluid.





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

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

14. REMOVE FRONT DISC BRAKE BLEEDER PLUG
a. Remove the front disc brake bleeder plug from the front disc brake cylinder sub-assembly.
15. REMOVE FRONT DISC BRAKE BLEEDER PLUG CAP
16. INSPECT BRAKE CYLINDER AND PISTON
a. Check the brake cylinder bore and front disc brake piston for rust or scoring.





17. INSPECT PAD LINING THICKNESS
a. Using a ruler, measure the pad lining thickness.
Standard thickness: 12.0 mm (0.472 inch)
Minimum thickness: 1.0 mm (0.039 inch)
18. INSPECT FRONT DISC BRAKE PAD SUPPORT PLATE
a. Inspect the front disc brake pad support plate (No.1) and front disc brake pad support plate (No.2). Make sure that they have sufficient rebound, no deformation, cracks or wear, and have had all rust and dirt cleaned off.





19. INSPECT DISC THICKNESS
a. Using a micrometer, measure the disc thickness.
Standard thickness: 28.0 mm (1.102 inch)
Minimum thickness: 26.0 mm (1.024 inch)





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

HINT: Select the installation position where the disc has the minimum runout.





22. INSPECT DISC RUNOUT
a. Temporarily fasten the disc with the hub nuts.
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
b. Using a dial indicator, measure the disc runout 10 mm (0.39 inch) away from the outer edge of the disc.
Maximum disc runout: 0.05 mm (0.0020 inch)
c. If the disc runout is the maximum value or greater, check the bearing play in the axial direction and check for the axle hub runout. If the bearing play and axle hub runout are normal, adjust the disc runout or grind it on a "On-car" brake lathe.
23. TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG
a. Temporarily install the front disc brake bleeder plug to the front disc brake cylinder sub-assembly.
24. INSTALL FRONT DISC BRAKE BLEEDER PLUG CAP
25. INSTALL PISTON SEAL
a. Apply lithium soap base glycol grease to a new piston seal.
b. Install the piston seal to the front disc brake cylinder sub-assembly.





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

NOTICE: Do not install the piston forcibly in the front disc brake cylinder sub-assembly.





27. INSTALL CYLINDER BOOT
a. Install a new cylinder boot to the front disc brake cylinder sub-assembly.

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

b. Using a screwdriver, install the set ring.

NOTICE: Do not damage the cylinder boot.





28. INSTALL FRONT DISC BRAKE BUSH DUST BOOT
a. Using soft jaws on the vise, hold the front disc brake cylinder mounting LH in the vise through aluminum plates.
b. Place front disc brake cylinder mounting LH in vise.
c. Apply lithium soap base glycol grease to the sealing surface of 2 new front disc brake bush dust boots.
d. Using a socket wrench (19 mm) and hammer, drive the 2 front disc brake bush dust boots to the front disc brake cylinder mounting LH.
29. INSTALL FRONT DISC BRAKE CYLINDER SLIDE BUSH
a. Apply the lithium soap base glycol grease to a new front disc brake cylinder slide bush.
b. Install the cylinder slide bush to the bottom side of the front disc brake cylinder slide pin (No.2).





30. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN
a. Apply the lithium soap base glycol grease to the sliding part and the sealing surface of the front disc brake cylinder slide pin (No. 1) and front disc brake cylinder slide pin (No.2)
b. Install the front disc brake cylinder slide pin (No.1) and front disc brake cylinder slide pin (No.2) to the front disc brake cylinder mounting LH.
c. Install the front disc brake cylinder slide pin (No.2) to the front disc brake cylinder mounting LH.





31. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING LH
a. Install the front disc brake cylinder mounting with the 2 bolts.
Torque: 107 Nm (1,090 kgf-cm, 79 ft. lbs.)
32. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE
a. Install the front disc brake pad support plate (No.1) and front disc brake pad support plate (No.2) to the front disc brake cylinder mounting LH.
33. INSTALL ANTI SQUEAL SHIM KIT FRONT

NOTICE: If necessary, replace the anti squeal shim kit when replacing the brake pad.

a. Apply disc brake grease to each anti squeal shim.
b. Install anti squeal shims on each pad.
c. Install the pad wear indicator plate facing upward, and install each pad.
34. INSTALL DISC BRAKE PAD KIT FRONT (PAD ONLY)
a. Install the disc brake pad kit front to the front disc brake cylinder mounting LH.

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





35. INSTALL FRONT DISC BRAKE CYLINDER SUB-ASSEMBLY
a. Install the front disc brake cylinder sub-assembly with the 2 bolts.
Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.)
b. Install a 2 new gaskets and flexible hose with the union bolt.
Torque: 29 Nm (296 kgf-cm, 21 ft. lbs.)

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

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



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