Operation CHARM: Car repair manuals for everyone.
Home >> Toyota >> 2005 >> Sienna AWD V6-3.3L (3MZ-FE) >> Repair and Diagnosis >> Brakes and Traction Control >> Disc Brake System >> Service and Repair >> Rear

Rear






REAR DISC BRAKE
OVERHAUL

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

1. REMOVE REAR WHEEL
2. DRAIN BRAKE FLUID

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





3. SEPARATE REAR BRAKE TUBE NO.4
a. Remove the clip and a disconnect, the rear brake flexible hose.
b. Using SST and spanner loosen the rear brake tube No.4.
SST 09023-00101





4. SEPARATE REAR LH FLEXIBLE HOSE
a. Using SST, remove the rear brake flexible hose.
SST 09023-12701





5. REMOVE DISC BRAKE CYLINDER ASSEMBLY REAR LH
a. Hold the rear disc brake cylinder slide pin and remove the 2 bolts.
b. Remove the disc brake cylinder assembly rear LH from the rear disc brake cylinder mounting LH.
6. REMOVE REAR DISC BRAKE CYLINDER SLIDE PIN
a. Remove the 2 rear disc brake cylinder slide pins from the rear disc brake cylinder mounting LH.
7. REMOVE REAR DISC BRAKE BUSH DUST BOOT
a. Remove the 2 rear disc brake bush dust boots.
8. REMOVE DISC BRAKE PAD KIT REAR (PAD ONLY)
a. Remove the disc brake pad kit rear.
9. REMOVE REAR DISC BRAKE ANTI SQUEAL SHIM KIT
a. Remove the anti squeal shim No.1 and anti squeal shim No.2 from each pad.
10. REMOVE REAR DISC BRAKE PAD SUPPORT PLATE
a. Remove the rear disc brake pad support plate (No.1) and rear disc brake pad support plate (No.2) from the rear disc brake cylinder mounting LH.
11. REMOVE REAR DISC BRAKE CYLINDER MOUNTING
a. Remove the bolts and rear disc brake cylinder mounting LH.





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





13. REMOVE REAR DISC BRAKE DISC BRAKE PISTON
a. Place a shop rug, between the rear disc brake piston and the disc brake cylinder.
b. Use compressed air to remove the rear disc brake piston from the disc brake cylinder.

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

NOTICE: Do not spatter the brake fluid.





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

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

15. REMOVE REAR DISC BRAKE BLEEDER PLUG CAP
16. REMOVE REAR DISC BRAKE BLEEDER PLUG
a. Remove the rear disc brake bleeder plug from the disc brake cylinder assembly rear LH.
17. INSPECT BRAKE CYLINDER AND PISTON
a. Check the brake cylinder bore and rear disc brake piston for rust or scoring.





18. INSPECT PAD LINING THICKNESS
a. Using a ruler, measure the pad lining thickness.
Standard thickness: 11.0 mm (0.433 inch)
Minimum thickness: 1.0 mm (0.039 inch)
19. INSPECT REAR DISC BRAKE PAD SUPPORT PLATE
a. Inspect the rear brake disc pad support plate (No.1) and rear brake disc 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.
20. INSPECT DISC THICKNESS
a. Using a micrometer, measure the disc thickness.
Standard thickness: 12.0 mm (0.472 inch)
Minimum thickness: 10.5 mm (0.413 inch)





21. REMOVE REAR DISC
a. Make matchmarks on the rear disc and the axle hub,
b. Remove the rear disc.
22. INSTALL REAR DISC
a. Aligning the matchmarks, install the rear disc.

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

23. REMOVE PARKING BRAKE SHOE ADJUSTING HOLE PLUG
24. INSTALL PARKING BRAKE SHOE ADJUSTING HOLE PLUG





25. 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: 0.10 mm (0.0039 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.
26. ADJUST PARKING BRAKE SHOE CLEARANCE
27. TEMPORARILY TIGHTEN REAR DISC BRAKE BLEEDER PLUG
a. Temporarily install the rear disc brake bleeder plug to the disc brake cylinder assembly rear LH.
28. INSTALL REAR DISC BRAKE BLEEDER PLUG CAP
29. 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 rear LH.





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

NOTICE: Do not install the piston forcibly in the disc brake cylinder.





31. INSTALL CYLINDER BOOT
a. Install a new cylinder boot to the rear 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.

32. INSTALL REAR DISC BRAKE BUSH DUST BOOT
a. Install the 2 rear disc brake bush dust boot to the disc brake cylinder mounting LH.
33. INSTALL REAR DISC BRAKE CYLINDER SLIDE PIN
a. Apply the lithium soap base glycol grease to the sealing surface of the 2 rear disc brake cylinder slide pins.
34. INSTALL REAR DISC BRAKE CYLINDER MOUNTING LH
a. Install the rear disc brake cylinder mounting LH with the 2 bolts.
Torque: 88 Nm (900 kgf-cm, 65 ft. lbs.)
35. INSTALL REAR DISC BRAKE PAD SUPPORT PLATE
a. Install the rear disc brake pad support plate (No.1) and rear disc brake pad support plate (No.2) to the rear disc brake cylinder mounting LH.
36. INSTALL REAR DISC BRAKE ANTI SQUEAL SHIM KIT

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

a. Apply disc brake grease to each anti squeal shim No.1.
b. Install anti squeal shims No.1 and anti squeal shim No.2 on each pad.
37. INSTALL DISC BRAKE PAD KIT REAR (PAD ONLY)
a. Install the brake pad kit rear to the rear disc brake cylinder mounting LH.

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

38. INSTALL DISC BRAKE CYLINDER ASSEMBLY REAR LH
a. Install the disc brake cylinder assembly rear LH with the 2 bolts.
Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.)





39. CONNECT REAR LH FLEXIBLE HOSE
a. Using SST, Install the rear brake flexible hose.
SST 09023-12701
Torque: 23 Nm (235 kgf-cm, 17 ft. lbs.)





40. CONNECT REAR BRAKE TUBE NO.4
a. Install the clip and connect the rear brake flexible hose.
b. Using SST and a spanner, connect the rear brake tube No.4.
SST 09023-00101
Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.)
41. FILL RESERVOIR WITH BRAKE FLUID
42. BLEED MASTER CYLINDER
SST 09023-00101
43. BLEED BRAKE LINE
44. CHECK FLUID LEVEL IN RESERVOIR
45. CHECK BRAKE FLUID LEAKAGE
46. INSTALL REAR WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)


pro multis · About Operation CHARM