Toyota Tundra. Manual — part 968

2009 BRAKES

Brake - Tundra

BRAKE SYSTEM

PRECAUTION

NOTE:



Make sure to replace each part properly. Improper installation or repair
could affect the performance of the brake system and cause a driving
hazard.



It is very important to keep the brake system parts and the work area clean
when repairing the brake system.



If the vehicle is equipped with a mobile communication system, refer to
PRECAUTION in the INTRODUCTION article.



Care must be taken when using magnets as they could affect the
performance of the speed sensors.



Since the brake line is one of the critical safety-related parts, be sure to
disassemble the components if a brake fluid leak is found. If any
abnormality is found, replace the component with a new one.



When removing brake components, cover the brake tube connections to
prevent foreign matter such as dust or dirt from entering the tubes.



Do not damage or deform the brake tubes when removing or installing
them.



When installing a brake tube grommet to the body, ensure that the brake
tube passes through the center of the grommet.



When installing a brake tube or flexible hose, ensure that it is not twisted
or bent.



If the fitting of the flexible hose does not match the groove on the bracket,
twist the hose slightly to insert it.



Flexible hoses must be free from absorber oil, grease, etc.



When installing a brake tube to a plastic clamp, ensure that the brake tube
is not loose or being pinched.



Do not reuse a clip or plastic clamp removed from a flexible hose.



After installing a brake tube and flexible hose, ensure that they do not
interfere with any other components.



Do not allow brake fluid to adhere to any painted surface such as the
vehicle body. If brake fluid leaks onto any painted surface, immediately
wash it off.



Follow these procedures when disconnecting the flexible hose and brake
tube.

a. Remove the clip.

2009 Toyota Tundra

2009 BRAKES Brake - Tundra

2009 Toyota Tundra

2009 BRAKES Brake - Tundra

b. Hold the flexible hose with a wrench. Using SST, disconnect the

brake tube without deforming the tube.

Fig. 1: Disconnecting Flexible Hose And Brake Tube
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.



Follow these procedures when connecting the flexible hose and brake
tube.

a. Hold the flexible hose with a wrench. Using SST, connect the brake

tube without deforming the tube.

b. Install a new clip.



Follow these procedures when connecting the brake tube and 2-way.

a. Support the 2-way to prevent deformation to the brake tube and

connect the brake tube to the 2-way with a union nut wrench.

b. Support the 2-way to prevent deformation to the brake tube and

install the bolt to fix the 2-way to the body.

2009 Toyota Tundra

2009 BRAKES Brake - Tundra

PROBLEM SYMPTOMS TABLE

HINT:

Use the table below to help determine the cause of the problem symptom. The potential causes of the symptoms
are listed in order of probability in the "Suspected Area" column of the table. Check each symptom by checking
the suspected areas in the order they are listed. Replace parts as necessary.

Brake system

BRAKE SYSTEM PROBLEM SYMPTOMS CHART

Fig. 2: Identifying Brake Tube And 2-Way Valve Bolt
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Symptom

Suspected Area

See

Low pedal or spongy pedal

Fluid leaks in brake system

-

Air in brake system

BRAKE FLUID

Front brake piston seals (worn or
damaged)

DISASSEMBLY

Rear brake piston seals (worn or
damaged)

DISASSEMBLY

Brake master cylinder (faulty)

REMOVAL

Brake drag

Brake pedal free play (minimum) INSTALLATION
Parking brake travel (adjustment
necessary)

INSTALLATION

Parking brake cable (sticking)

REMOVAL

Parking brake shoe clearance
(adjustment necessary)

REASSEMBLY

Front brake pad (cracked or
distorted)

REMOVAL

Rear brake pad (cracked or
distorted)

REMOVAL

Parking brake lining (cracked or
distorted)

PARKING BRAKE
ASSEMBLY

Front brake piston (stuck or
frozen)

DISASSEMBLY

Rear brake piston (stuck or frozen) DISASSEMBLY
Parking brake shoe return tension
spring

PARKING BRAKE
ASSEMBLY

Vacuum leaks in booster system

ON-VEHICLE INSPECTION

Brake master cylinder (faulty)

REMOVAL

Front brake piston (stuck or
frozen)

DISASSEMBLY

Rear brake piston (stuck or frozen) DISASSEMBLY

2009 Toyota Tundra

2009 BRAKES Brake - Tundra

BRAKE FLUID

ON-VEHICLE INSPECTION

1. CHECK BRAKE FLUID LEVEL IN RESERVOIR

a. Check the fluid level and add fluid if necessary.

Fluid: SAE J1703 or FMVSS No. 116 DOT3

Brake pull

Front brake pad (oily, cracked or
distorted)

REMOVAL

Rear brake pad (oily, cracked or
distorted)

REMOVAL

Parking brake lining (oily, cracked
or distorted)

PARKING BRAKE
ASSEMBLY

Front brake disc (uneven wear)

REMOVAL

Rear brake disc (uneven wear)

REMOVAL

Hard pedal but braking inefficient

Front brake pad (worn, cracked,
distorted, oily or glazed)

REMOVAL

Rear brake pad (worn, cracked,
distorted, oily or glazed)

REMOVAL

Parking brake lining (worn,
cracked, distorted, oily or glazed)

PARKING BRAKE
ASSEMBLY

Front brake disc (uneven wear)

REMOVAL

Rear brake disc (uneven wear)

REMOVAL

Vacuum leaks in booster system

ON-VEHICLE INSPECTION

Noise from brakes

Front brake pad (cracked,
distorted, dirty or glazed)

REMOVAL

Rear brake pad (cracked, distorted,
dirty or glazed)

REMOVAL

Rear disc brake pad support plate
(loose)

REMOVAL

Front brake installation bolt
(loose)

FRONT BRAKE FLEXIBLE
HOSE

Rear brake installation bolt (loose) REAR BRAKE FLEXIBLE

HOSE

Front brake disc (scored)

REMOVAL

Rear brake disc (scored)

REMOVAL

Parking brake shoe return tension
spring (faulty)

PARKING BRAKE
ASSEMBLY

Front brake anti-squeal shim
(damaged)

REMOVAL

Rear brake anti-squeal shim
(damaged)

REMOVAL

2009 Toyota Tundra

2009 BRAKES Brake - Tundra