Page 529 of 3115
BR12F-01
- BRAKEBRAKE SYSTEM
BR-1
2137 Author: Date:
2004 LAND CRUISER (RM1071U)
BRAKE SYSTEM
PRECAUTION
Care must be taken to replace each part properly as it could affect the performance of the brake
system and result in a driving hazard. Replace the parts with parts of the same part number or
equivalent.
It is very important to keep parts and the area clean when repairing the brake system.
If the vehicle is equipped with a mobile communication system, refer to the precautions in the
IN section.
Page 530 of 3115
BR0JJ-06
F05025
11 (110, 8)
74 (750, 54)
Bleeder Plug
Brake Caliper
Inner Pad Clip
Boot Piston Seal
Piston
Set Ring
Axle Hub Disc
N´m (kgf´cm, ft´lbf): Specified torque
Lithium soap base glycol grease
Disc brake grease Non-reusable part
30 (310, 22)
GasketOuter PadPad Retainer Pad Retainer Clip
Anti-squeal ShimPad Retainer
Anti-squeal Shim
123 (1,250, 90)
x5
Outer Bearing
Thrust Washer
Adjusting Nut Lock Washer
Lock Nut
Gasket
Flange
Snap Ring
Grease Cap
x6
Plate Washer
33 (335, 24)
Cone WasherPin
64 (650, 47)
Outer Race
Inner Bearing
Outer Race
Oil seal
BR-18
- BRAKEFRONT BRAKE CALIPER
2154 Author: Date:
2004 LAND CRUISER (RM1071U)
FRONT BRAKE CALIPER
COMPONENTS
Page 531 of 3115
BR0JL-03
F04972
Z09007
170mm
(6.70in)50mm
(1.97in)
30mm
(1.18in)
BR0213
F04973
BR-20
- BRAKEFRONT BRAKE CALIPER
2156 Author: Date:
2004 LAND CRUISER (RM1071U)
DISASSEMBLY
1. REMOVE CYLINDER BOOT SET RINGS AND CYL-
INDER BOOTS
Using a screwdriver, remove the 4 cylinder boot set rings and
4 cylinder boots from the caliper.
2. REMOVE PISTONS FROM CYLINDER
(a) Prepare the wooden plate to hold the pistons.
(b) Place the plate between the pistons and insert a pad at
one side.
(c) Use compressed air to remove the pistons alternately
from the cylinder.
CAUTION:
Do not place your fingers in front of the piston when using
compressed air.
3. REMOVE PISTON SEALS FROM BRAKE CYLINDER
Using a screwdriver, remove the 4 piston seals from the cylin-
der.
Page 532 of 3115

F04980
BR0JM-06
F04981
F04982
- BRAKEFRONT BRAKE CALIPER
BR-21
2157 Author: Date:
2004 LAND CRUISER (RM1071U)
INSPECTION
1. MEASURE PAD LINING THICKNESS
Using a ruler, measure the pad lining thickness.
Standard thickness: 11.5 mm (0.453 in.)
Minimum thickness: 1.0 mm (0.039 in.)
Replace the pad if the pad's thickness is at the minimum or if
it shows signs of uneven wear.
2. MEASURE DISC THICKNESS
Using a micrometer, measure the disc thickness.
Standard thickness: 32.0 mm (1.260 in.)
Minimum thickness: 30.0 mm (1.181 in.)
Replace the disc if the thickness of the disc is at the minimum
thickness or less. Replace the disc or grind it on a lathe if it is
scored or is worn unevenly.
3. MEASURE DISC RUNOUT
Using a dial indicator, measure the disc runout at a position 10
mm (0.39 in.) from the out side edge.
Maximum disc runout: 0.07 mm (0.0028 in.)
If the bearing play and axle hub runout are not abnormal, re-
place the disc or grind it on an ºOn-Car brake latheº.
HINT:
Before measuring the runout, confirm that the front bearing pre-
load is within the specification (See page SA-16).
4. IF NECESSARY, REPLACE DISC
(a) Remove the front axle hub (See page SA-12).
(b) Remove the disc from the axle hub (See pageSA-13).
(c) Install a new disc and torque the 5 bolts.
Torque: 74 N´m (750 kgf´cm, 54 ft´lbf)
(d) Install the axle hub and adjust the front bearing preload
(See page SA-16).
Page 533 of 3115
BR0JO-06
- BRAKEFRONT BRAKE CALIPER
BR-23
2159 Author: Date:
2004 LAND CRUISER (RM1071U)
INSTALLATION
Installation is in the reverse order of removal (See page BR-19).
HINT:
After installation, fill the brake reservoir with brake fluid and bleed brake system (See page BR-4).
Check for leaks.
Page 534 of 3115
BR0JN-04
BR-22
- BRAKEFRONT BRAKE CALIPER
2158 Author: Date:
2004 LAND CRUISER (RM1071U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page BR-20).
HINT:
Apply lithium soap base glycol grease to the parts indicated by the arrows (See page BR-18).
Page 535 of 3115
BR0TA-04
F04974
F04975
- BRAKEFRONT BRAKE CALIPER
BR-19
2155 Author: Date:
2004 LAND CRUISER (RM1071U)
REMOVAL
1. REMOVE FRONT WHEEL
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
2. DISCONNECT BRAKE LINE
(a) Remove the union bolt and 2 gaskets from the caliper,
then disconnect the flexible hose from the caliper.
Torque: 30 N´m (310 kgf´cm, 22 ft´lbf)
(b) Use a container to catch the brake fluid as it drains out.
3. REMOVE CALIPER
Remove the 2 mounting bolts and remove the caliper.
Torque: 123 N´m (1,250 kgf´cm, 90 ft´lbf)
4. REMOVE CLIP AND 2 PINS
5. REMOVE 2 PAD RETAINER CLIPS
6. REMOVE 2 PADS, ANTI-SQUEAL SHIMS AND PAD
RETAINERS
Page 536 of 3115
BR0JH-03
F04971
Anti-squeal Shim
Pin Pad Retainer Clip
Clip
Anti-squeal Shim
Pad Retainer Pad Retainer
Outer Pad Inner Pad
Disc brake grease
- BRAKEFRONT BRAKE PAD
BR-15
2151 Author: Date:
2004 LAND CRUISER (RM1071U)
FRONT BRAKE PAD
COMPONENTS