Toyota Tundra. Manual — part 978

HINT:

Tape the screwdriver tip before use.

Fig. 55: Removing Piston Seals
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

4. REMOVE FRONT DISC BRAKE BLEEDER PLUG CAP

5. REMOVE FRONT DISC BRAKE BLEEDER PLUG

INSPECTION

1. CHECK BRAKE CYLINDER AND PISTON

a. Check the cylinder bore and piston for rust or scoring.

If necessary, replace the disc brake caliper assembly.

2. CHECK PAD LINING THICKNESS

a. Using a ruler, measure the pad lining thickness.

Standard thickness: 11.9 mm (0.469 in.)

Minimum thickness: 1.0 mm (0.0394 in.)

If the pad lining thickness is less than the minimum, replace the pad.

HINT:

Be sure to check the wear on the front disc after replacing the brake pad with a new one.

NOTE:

Do not damage the inner cylinder and cylinder groove.

2009 Toyota Tundra

2009 BRAKES Brake - Tundra

Fig. 56: Measuring Pad Lining Thickness
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

3. CHECK FRONT DISC BRAKE ANTI-RATTLE SPRING

a. Use brake cleaner to clean the front disc brake anti-rattle spring. Check for deformation and cracks.

b. When installing the front disc brake anti-rattle spring to the front disc brake caliper, check that the

spring's force is applied to the hole pin and brake pad.

4. CHECK DISC THICKNESS

a. Using a micrometer, measure the disc thickness.

Standard thickness: 32.0 mm (1.26 in.)

Minimum thickness: 29.0 mm (1.14 in.)

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

Fig. 57: Measuring Disc Thickness
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

5. CHECK DISC RUNOUT

a. Using SST to hold the disc, fix the disc in place with the 5 hub nuts.

SST 09330-00021

Torque:

for Aluminum Whee l

2009 Toyota Tundra

2009 BRAKES Brake - Tundra

131 N*m (1336 kgf*cm, 97 ft.*lbf)

for Steel Wheel

209 N*m (2131 kgf*cm, 154 ft.*lbf)

Fig. 58: Holding Disc Using SST
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

b. Using a dial indicator, measure the disc runout 10 mm inside (0.394 in.) the outer edge of the disc.

Maximum disc runout: 0.05 mm (0.00197 in.)

Fig. 59: Measuring Disc Runout
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

c. If the runout exceeds the maximum value, change the installation positions of the disc and axle so

that the runout will become minimal. If the runout exceeds the maximum even when the installation
positions are changed, check the bearing looseness in the axial direction (see ON-VEHICLE
INSPECTION ) and the axle hub runout (see ON-VEHICLE INSPECTION ). If the bearing
looseness and the axle hub runout are normal, and if the disc thickness is not within the specified
range, grind the disc. If the disc thickness is less than the minimum, replace the disc.

d. Remove the front disc.

REASSEMBLY

HINT:

2009 Toyota Tundra

2009 BRAKES Brake - Tundra



Use the same procedures for the LH side and RH side.



The procedures listed below are for the LH side.

1. TEMPORARILY INSTALL FRONT DISC BRAKE BLEEDER PLUG

a. Temporarily install the bleeder plug to the disc brake caliper.

HINT:

The bleeder plug will be tightened to a torque specification in the "BLEED AIR FROM BRAKE
LINE" in REPLACEMENT.

2. INSTALL FRONT DISC BRAKE BLEEDER PLUG CAP

3. INSTALL PISTON SEAL

a. Apply a light layer of lithium soap base glycol grease to the entire inner and outer circumference of

4 new piston seals.

b. Install the 4 piston seals to the disc brake caliper.

Fig. 60: Installing Piston Seals
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

4. REMOVE AND INSTALL FRONT DISC BRAKE PISTON

a. Apply lithium soap base glycol grease to the 4 front disc brake pistons and 4 new cylinder boots.

b. Apply a light layer of lithium soap base glycol grease to the entire outer circumference of the 4

front disc brake pistons where they contact the cylinder boots and front disc brake caliper.

c. Install the 4 cylinder boots to the 4 front disc brake pistons.

d. Install the 4 front disc brake pistons to the front disc brake caliper.

NOTE:

Do not forcibly install the piston into the disc brake caliper.

2009 Toyota Tundra

2009 BRAKES Brake - Tundra