Page 1039 of 4592
F07226
1MZ±FE engine:
Caliper
Torque Plate
Disc
PistonSliding pin
Sliding Bushing
Dust Boot
Pad Support Plate Sliding Pin
Dust Boot
Pad Wear Indicator Plate
Inner Pad Piston Seal
BootSet Ring
Outer Pad
Inner Anti±squeal Shim
Anti±squeal Shim
Disc Brake grease Lithium soap base glycol grease Non±reusable part
N´m (kgf´cm, ft´lbf)
: Specified torque Bleeder Plug
34 (350, 25)
107 (1,090, 79)29 (300, 21)
8.3 (85, 74 in.´lbf)
29 (300, 21)
Gasket
± BRAKEFRONT BRAKE CALIPER
BR±25
2048 Author: Date:
Page 1040 of 4592
BR0AR±03
R02840
BR±26
± BRAKEFRONT BRAKE CALIPER
2049 Author: Date:
REMOVAL
1. REMOVE FRONT WHEEL
Torque: 103 N´m (1.050 kgf´cm, 76 ft´lbf)
2. DISCONNECT FLEXIBLE HOSE
(a) Remove the union bolt and 2 gaskets from the caliper,
then disconnect the flexible hose from the caliper.
Torque: 29 N´m (300 kgf´cm, 21 ft´lbf)
HINT:
At the time of installation, please refer to the following item.
Install the flexible hose lock securely in the lock hole in the cali-
per.
(b) Use a container to catch the brake fluid as it drains out.
3. REMOVE CALIPER
(a) 5S±FE engine:
Hold the sliding pin and loosen the 2 installation bolts, and
remove the installation bolts.
(b) 1MZ±FE engine:
Remove the 2 installation bolts.
Torque: 34 N´m (350 kgf´cm, 25 ft´lbf)
4. 5S±FE engine:
REMOVE 2 ANTI±SQUEAL SPRINGS
5. REMOVE 2 BRAKE PADS WITH ANTI±SQUEAL
SHIMS
6. 1MZ±FE engine:
REMOVE 2 PAD SUPPORT PLATES
7. 5S±FE engine:
REMOVE 4 PAD SUPPORT PLATES
Page 1041 of 4592

BR0AS±03
R00121
R00122
R00123
R02877
± BRAKEFRONT BRAKE CALIPER
BR±27
2050 Author: Date:
DISASSEMBLY
1. REMOVE SET RING AND CYLINDER BOOT
Using a screwdriver, remove the set ring and cylinder boot from
the caliper.
2. REMOVE PISTON
(a) Place a piece of cloth or similar, between the piston and
the caliper.
(b) Use compressed air to remove the piston from the cylin-
der.
CAUTION:
Do not place your fingers in front of the piston when using
compressed air.
3. REMOVE PISTON SEAL
Using a screwdriver, remove the piston seal from the cylinder.
4. REMOVE SLIDING PINS AND DUST BOOTS
(a) Remove the 2 sliding pins from the torque plate.
NOTICE:
At the time of reassembly, please refer to the following
item.
Insert the sliding pin with sliding bushing into the bottom
side (5S±FE engine) or top side (1MZ±FE engine).
(b) Using a screwdriver and hammer, tap out the 2 dust
boots.
HINT:
At the time of reassembly, please refer to the following item.
Use a 22 mm (5S±FE engine) or 24 mm (1MZ±FE engine) sock-
et wrench and tap in 2 new dust boots into the torque plate.
NOTICE:
At the time of reassembly, please refer to the following
item.
Check that the metal plate portion of the dust boot fits
snugly in the torque plate.
Page 1042 of 4592

F06988
BR0AT±03
R02878
R02879
R02880
BR±28
± BRAKEFRONT BRAKE CALIPER
2051 Author: Date:
INSPECTION
1. MEASURE PAD LINING THICKNESS
Using a ruler, measure the pad lining thickness.
Standard thickness:
5S±FE engine: 12.0 mm (0.472 in.)
1MZ±FE engine: 11.0 mm (0.433 in.)
Minimum thickness: 1.0 mm (0.039 in.)
Replace the pad if the pad's thickness is at the minimum thick-
ness or less, or if the pad has severe and uneven wear.
2. MEASURE DISC THICKNESS
Using a micrometer, measure the disc thickness.
Standard thickness: 28.0 mm (1.102 in.)
Minimum thickness: 26.0 mm (1.024 in.)
Replace the disc if the disc's thickness is at the minimum thick-
ness or less. Replace the disc or grind it on a lathe if it is badly
scored or worn unevenly.
3. MEASURE DISC RUNOUT
Using a dial indicator, measure disc runout 10 mm (0.39 in.)
away from the outer edge of the disc.
Maximum disc runout: 0.05 mm (0.0020 in.)
If the disc's runout is the maximum value or greater, check the
bearing play in the axial direction and check the axle hub runout
(See page SA±10). If the bearing play and axle hub runout are
not abnormal, adjust the disc runout or grind it on a ºOn±Carº
brake lathe.
4. IF NECESSARY, ADJUST DISC RUNOUT
(a) Remove the torque plate from the knuckle.
(b) Remove the hub nuts and the disc. Reinstall the disc in
the position turned 1/5 from its original position on the
hub. Install and torque the hub nuts.
Remeasure the disc runout. Make a note of the runout
and the disc's position on the hub.
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
(c) Repeat (b) until the disc has been installed on the 3 re-
maining hub positions.
(d) If the minimum runout recorded in (b) and (c) is less than
0.05 mm (0.0020 in.), install the disc in that position.
(e) If the minimum runout recorded in (b) and (c) is greater
than 0.05 mm (0.0020 in.), replace the disc and repeat
step 3.
(f) Install the torque plate and torque the mounting bolts.
Torque: 107 N´m (1,090 kgf´cm, 79 ft´lbf)
Page 1043 of 4592
BR0AU±01
± BRAKEFRONT BRAKE CALIPER
BR±29
2052 Author: Date:
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page BR±27).
NOTICE:
Apply lithium soap base glycol grease to the parts indicated by arrows (See page BR±24).
Page 1044 of 4592
BR0AV±02
BR±30
± BRAKEFRONT BRAKE CALIPER
2053 Author: Date:
INSTALLATION
Installation is in the reverse order of removal (See page BR±26).
HINT:
After installation, fill the brake reservoir with brake fluid, bleed the brake system (See page BR±4).
Check for leaks.
Page 1045 of 4592
BR0AW±03
W03258
Plug
SpringWheel Cylinder
BootAdjuster
Cup
PistonC±washer Inspection Hole
Plug
Pin
Front Shoe
Cup
Shoe Hold±down Spring Adjuster
Rear Shoe
Anchor SpringParking Brake Lever
Automatic Adjusting Lever
E±ring
Adjusting Lever Spring Bleeder Plug
High temperature grease Lithium soap base glycol grease Non±reusable part
N´m (kgf´cm, ft´lbf): Specified torque
8.3 (85, 74 in.´lbf)
10 (100, 7)
± BRAKEREAR DRUM BRAKE
BR±31
2054 Author: Date:
REAR DRUM BRAKE
COMPONENTS
Page 1046 of 4592

BR0AX±03
BR1532
R00285
BR1534
SST
BR1535
SST BR±32
± BRAKEREAR DRUM BRAKE
2055 Author: Date:
REMOVAL
1. INSPECT SHOE LINING THICKNESS
Remove the inspection hole plug, and check the shoe lining
thickness through the hole.
If less than the minimum, replace the shoes.
Minimum thickness: 1.0 mm (0.039 in.)
2. REMOVE REAR WHEEL
3. REMOVE BRAKE DRUM
(a) Release the parking brake lever and remove the brake
drum.
HINT:
If the brake drum cannot be removed easily, do the following
steps.
(b) Insert a bent wire or equivalent through the hole in the
brake drum, and hold the automatic adjusting lever away
from the adjuster.
(c) Using a screwdriver, reduce the brake shoe adjustment
by turning the adjuster.
4. REMOVE FRONT SHOE
(a) Using SST, disconnect the return spring.
SST 09703±30010
(b) Using SST, remove the shoe hold±down spring, 2 cups
and pin.
SST 09718±00010
(c) Disconnect the anchor spring from the front shoe and re-
move the front shoe.
(d) Remove the anchor spring from the rear shoe.