Disassembly Of Cylinder

1. REMOVE SLIDING BUSHING AND BOOT

2007 Rav4 Knuckle Bushings

2. REMOVE MAIN PIN BOOT WITH A CHISEL

3. REMOVE PISTON FROM CYLINDER

Use compressed air to remove the piston from the cylinder.

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

4. REMOVE CYLINDER BOOT AND SET RING FROM CYLINDER

5. REMOVE PISTON SEAL FROM CYLINDER

INSPECTION OF FRONT BRAKE COMPONENTS

1. MEASURE PAD LINING THICKNESS

Standard thickness: 10.5 mm (0.413 in.) Minimum thickness: 3.0 mm (0.118 in.)

Replace the pad if the thickness is less than the minimum (the 1.0 mm slit is no longer visible) or if it shows sign of uneven wear.

2. MEASURE ROTOR DISC THICKNESS

Standard thickness: 20.0 mm (0.787 in.) Minimum thickness: 19.0 mm (0.748 in.)

If the disc thickness is less than minimum, replace the disc.

3. MEASURE ROTOR DISC RUNOUT

Measure the rotor disc runout at 10 mm (0.39 in.) from the outer edge of rotor disc.

Maximum disc runout: 0.15 mm (0.0059 in.)

If the runout is greater than the maximum, replace the disc.

NOTE: Make sure the front bearing is adjusted correctly.

4. IF NECESSARY, REPLACE ROTOR DISC

(a) Remove the torque plate from the knuckle,

(c) Remove the disc from the axle hub.

(d) Install a new rotor disc. Torque four bolts. Torque: 650 kgcm {47 ft-lb, 64 N m)

(e) Install the axle hub and adjust the front bearing preload. (See page FA-8)

(f) Install the torque plate onto the knuckle. Torque: 925 kg-cm (67 ft-lb, 91 N m)

ASSEMBLY OF CYLINDER

1. APPLY LITHIUM SOAP BASE GLYCOL GREASE TO FOLLOWING PARTS:

(a) Main pin boot

(b) Sliding pin and boot

(c) Piston seal and piston

2. INSTALL PISTON SEAL AND PISTON IN CYLINDER

3. INSTALL CYLINDER BOOT AND SET RING IN CYLINDER

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INSTALL MAIN PIN BOOT

Using a 21-mm socket wrench, press in the boot.

INSTALL DUST BOOT AND SLIDING BUSHING

(a) Install the dust boot.

NOTE: Be careful that the seal does not fold under.

(b) Install the bushing into the boot facing the flange toward the inside.

FRONT BRAKE REPLACEMENT OF BRAKE PADS BR-14

INSTALLATION OF CYLINDER

1. INSTALL FOLLOWING PARTS:

(a) Pad support plate

(b) Pad guide plates

(c) Anti-rattle springs

(d) Brake pads

(e) Anti-squeal shim

2. INSTALL CYLINDER

(a) Install the cylinder onto the main pin.

NOTE: Make sure that the boot end is installed into the groove of the main pin.

(b) Install the cylinder over the brake pads.

3. INSTALL CYLINDER INSTALLATION BOLTS

Install the cylinder installation bolts, torque one bolt.

NOTE: Insert the installation bolt into the cylinder carefully so as not to wedge the boot.

4. CONNECT BRAKE LINE

(a) Connect the brake hose to the cylinder. Torque: 235 kg-cm (17 ft-lb, 23 N m)

(b) Using SST, connect brake hose to the brake tube. SST 09751-36011

5. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM (See page BR-7)

Celica Brake Replacement Diagram

Cylinder with Bracket

Installation Bolt I 200 (14 20T\

Sliding Bushing Boot

Cylinder

Piston

Pad Guide Plate Anti-Rattle Spring

Anti-Squeal Shim

Pad Support Plate

Pad Guide Plate

Rotor Disc Specified torque

Anti-Rattle Sprir>g

REPLACEMENT OF BRAKE PADS

NOTE: If a squealing noise occurs from the brakes white driving, check the pad wear indicator. If there are traces of the indicator contacting the rotor disc, the disc pad should be replaced.

Rotor Disc

Pad Wear Irvdicator

DRAW OUT A SMALL AMOUNT OF BRAKE FLUID

UNSCREW CYLINDER INSTALLATION BOLT

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