Brake Job: Toyota Prius: Brake and Front End

3 Jan 2015 | Author: | Comments Off on Brake Job: Toyota Prius: Brake and Front End

Brake Job: Toyota

Does performing a pad replacement on a Prius scare you? it should; if you treat it like other vehicle. But, if you a few things ahead of time, the job can be like any other brake

Do not worry about high Worry about angry due to comebacks because the brake/ABS is on. Servicing a Prius does not many special tools to a front brake pad replacement. normal hand tools are and maybe a scan tool and that can read chassis if you are unlucky or have to replace components.

But, it is possible, to Toyota, to replace pads a scan tool.

There are basic concepts that must be aware of before push back the pistons on the calipers. First, the most basic aspect to grasp for any is that the Prius braking has pressure sensors at the master and the outputs for wheels. These check the pressure and any anomalies the two pressures will cause a code to be set.

Second, the driver is pushing on the brake it might not be producing hydraulic force at the wheel. The system is the … and pressure generated at the pedal and translating that braking force created by a The system is not a full-time brake-by-wire

Hydraulic brakes are used hard stops and at speeds 10 mph. When the regenerative is engaged, it will give the feedback with a device the #x201C;… simulator.#x201D;

Last, if the engine is off and the car is not moving, there is hydraulic pressure in some of the The Prius can drive without the combustion engine running. even if the car is in park without the running and the keys in the ignition, the may start to charge the battery or run the system.

The keys need to be out and from the vehicle during If you keep these concepts in the of your mind, you should be to perform any brake service the right tools.

Prius Models

The Prius was in 2001. The rotor and caliper are the as the Echo, Scion Xa/Xb and In 2004, Toyota changed the system when it upgraded the and electric motor.

The most difference is the lack of a vacuum booster. In 2004, a different ECU and accumulator and pump now provided the

At the wheel, the system stayed the in regard to the rotor and caliper. the brake pad characteristics were for better longevity and corrosion

At the rear are drum brakes any regenerative braking. The rear brake is almost bullet-proof. there have been problems with the emergency/parking cables and the electric motor actuates the system.

In TSB BR002-07, it how to resolve problems with the light staying illuminated the emergency/parking brake has been This procedure will a scan tool

The Pads

It is not to find a Prius with or 100,000-miles with the original set of This is due to regenerative braking the majority of braking force. this does not mean other components, like and rubber seals/boots, can#x2019;t sooner.

The Prius has unique for the brake system. On 2001-2004 the hydraulic brakes were not until the vehicle was below 7 mph or if the had to make a hard stop.

The of the time, the pads never conventional operating temperatures and could occur between the plate and friction material due to the that the pads never out. On some vehicles, the between the friction material and plate would cause a separation.

Always use a high-quality pad for the and other hybrid applications to problems. It is not a question of better It is a question of quality and engineering.

it is impossible to perform a conventional procedure on the test drive, sure the manufacturer promises performance right out of the box. applying a non-direction finish a ball hone will the new pads evenly deposit a of friction material to the new rotor.

The Prius use a two-part shim. The piece is the anti-noise layer. The part provides lubrication and as a bearing. The two shims#x2019; contact float on the lube and slide application.

Always replace the and do not reuse an old shim!

There is special about servicing the on this vehicle. But, if you are to use an on-the-car brake lathe, sure the system is off for two minutes. on-the-car brake lathes below the speed threshold of the ability to generate voltage.

that have excessive or thickness variation can cause pulsations in the brake circuit. irregularities can cause the pressure to trigger trouble codes thru C1344 that a hydraulic circuit malfunction.

Components If you have to replace a wheel cylinder or brake you must have a scan that can clear codes and the ABS pump during bleeding. or #x201C;one man#x201D; bleeding not work on this vehicle due to the and solenoids that manage the braking. Also, the system be deactivated to prevent damage the

Also, read all of the precautions in the information before attempting to any hydraulic component.

Brake Pad

Lift the car and remove the wheels.

If that does not involve fluid bleeding, such as brake pad replacement, is started two or more after the power is turned off, brake (ECB) prohibition/deactivation is not necessary.

it is a good practice when on vehicles with advanced ABS and Control systems to remove the from the vehicle and place in a room, like at the front

Remove the two bolts and lift the disc brake caliper the pin slides. Make sure you have a thin 17mm to get at the bolt hex on the inner part of the pin. Secure the caliper to the with a hook or strap.

Remove the pads and inspect the material for glazing, corrosion, lift or other mechanical Using a ruler, measure the pad thickness from the base of the plate to the friction surface. make sure the inside and pads are evenly worn.

thickness: 11.0 mm (0.433

Minimum thickness: 1.0 mm (0.039

Minimum thickness: 20.0 mm in.).

Check for runout by a dial indicator 10 mm away the outer edge of the rotor. disc runout: 0.05 mm in.). Before removing the mark the high and low points of Also, mark the rotor#x2019;s on the hub. If you do this, you can change positions of the rotor and axle so the runout will be reduced.

the rotor has been removed, the runout in the face of the hub and mark the and low points.

Machine the rotor either a bench or on-the-car lathe.

Install shims on the new pads. If you are using original-style apply high temperature brake grease to the area the anti-squeal shim No.1 contact. Install the two anti-squeal No. 1, and the two anti-squeal shims No.

2 to the front brake pads.

Do not use excessive of grease that can contaminate the material once the brakes been heated.

Install the support brackets with the two Torque: 109 Nm, 81 ft/lbs).

Install disc brake cylinder pin. Toyota recommends soap-base glycol grease. the front disc brake slide pin into the dust and install it.

Make sure the boot#x2019;s seals are in the grooves on the

Install the abutment clips on the of the caliper bracket. A high brake specific grease can be on the surfaces the make contact the tabs or ears of the pads. only a very light

Install the pads in the caliper Toyota advises that the (abutment clip) have rebound when installing the Also, check that the pad not have too much play installation.

This can lead to drag and increased fuel

Gently push in the caliper only enough to fit over the new and shims. Toyota says it is not necessary to crack the bleeders this procedure and doing so cause more problems it solves. If you feel comfortable the brake hose and cracking the to remove displaced brake it can be done this way.

See TSB for more information.

Install the calipers. Torque: 34 Nm or 25 ft/lbs).

front wheels. Torque: 103 Nm or 76

With the car still powered with the key out of the ignition, … the several times to bring the in contact with the rotor.

fluid level in the reservoir. the brake fluid level to the MAX with the power switch on The brake fluid level be adjusted to the MAX line.

Test the vehicle. Make sure you perform several stops to 0 mph and at one hard stop. If the ABS warning does not come on, you are finished.

If an ABS does come on, you will to perform some additional

ABS Light On?

If the ABS light did come on the test drive, disconnecting the is not the way to clear the codes. Yes, it clear some codes, but you have to recalibrate the steering sensor and other items, the automatic power windows, stop functioning.

What during the test drive is the pressure sensors at the wheel an abnormal reading when the system was first engaged. The may have detected low pressure extra fluid is required to the piston into contact the rotor, or residual pressure you pushing the piston back. may be stored if brake fluid wheel cylinder vibrates due to wear of the brake disc or foreign matter enters the valve.

Toyota has issued a Technical Bulletin BR012-06 on the topic. It #x201C;When replacing the brake on an ECB (Electronically Controlled Brake) equipped vehicle, retracting the piston and installing new brake may cause trouble codes to set the time the brake pedal is

If any of the following four trouble are set, all the codes need to be and another test drive to verify the code has been

C1341 Front Hydraulic RH Malfunction

C1342 Front System LH Malfunction

C1343 Hydraulic System RH Malfunction

Rear Hydraulic System LH

If you do not have a scan tool, it is to clear the codes with Service Tool (SST) (Basically a fancy jumper

(a) Using SST, connect TC and CG of the DLC3.

(b) Turn the power ON (READY).

(c) Clear the DTCs in the ECU by depressing the brake pedal times or more within seconds.

(d) Check that the light indicates a normal code.

(e) Remove SST.

Clearing the DTCs cannot be by removing the cable from the (-) battery terminal or the ECU-IG


In May 2008, Toyota that its worldwide cumulative of the Prius had passed the 1 million Nearly 60% of all Prius sales been in North America 183,800 vehicles were in 2007. This is a significant for shops as the age of the hybrid fleet to age.

You will not have to insulated gloves and use rubber-coated to work on the brake system, but you have to arm yourself with


TSB BR002-07: Parking Brake Light stays illuminated the parking brake pedal is

Models: 2004 #150;2007

Some 2004 #150; model year Prius customers may complain that the Brake Warning Light illuminated after the parking pedal is released. The parking assembly, which includes the brake switch, has been to correct this condition. Use the repair procedure to remove and the parking brake pedal

(Includes 2004 #150; model year Prius produced BEFORE the production effective on VINs JTDKB20U#73249043 JTDKB20U#77632091.)

Repair Procedure

the customer#x2019;s complaint that the Brake Warning Light illuminated after the parking pedal is released.

Check to see if the brake switch is loose the plastic guide pin for the parking switch is broken. This can the switch to swivel out of position and NO make contact with the lever to engage the parking switch and open the circuit.

the parking brake pedal if the condition in step 2 is found. to the repair manual for the procedures for Brake Control Pedal Overhaul.#x201D;

TSB BR002-07: Brake Noise

Covers: 2004 2007 Prius Some #150; 2007 model Prius vehicles may exhibit a noise when pressing or the brake pedal. This may only be audible when the is in #x201C;READY#x201D; mode and the vehicle is not Brake system performance is not by this noise.

Use the following to address this concern.

noise condition by pressing/releasing the pedal.

Bleed the brake with a scan tool and the repair procedure. If the noise is NO present when pressing/releasing the pedal, the repair is complete. If the is still present, go to step 3.

If the is still present, replace the Actuator Assembly.

Refer to source of repair information for the procedure.

Road test for operation.

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