Upgrade your early Tundra Brakes In 1 hour

[MEvang]

This is for those of you who have wondered if you could do the overly complicated brake upgrade in the Toyota TSB BR004-02. The answer is yes, anyone with simple mechanical skills can do it and it can be done in about one hour or so and much cheaper then you have been told.
The problems:
1. If you buy all the parts listed in the TBS from Toyota you will pay out well over $1000.00. 2. The bulletin overly complicates the install, as it require that you replace the two backing plates. Then makes it worse by requiring the hub and bearing be removed to do this.
This is simply unreasonable and unnecessary.
How to save money and make it simple:
1. I researched this and found that replacing the backing plates is completely unnecessary The new caliper are only slightly larger and require just a little trimming of the backing plates to fit. All you need is a tin snips and a silver marker. This make it a simple swap.
2. Remanufactured calipers are now becoming available for the Tundra. Sure you will most likely have to pay the core charge but if this save haft the price of a new unit then it's still a great deal. Make sure when you go looking that you ask for the larger or upgraded calipers, otherwise you might get the same ones you have now.
What's needed and were to get it:
I have been searching for a good source of a quality remanufactured caliper for this swap. I know you can find some sources on the net. This is fine, but I discover that a friend of mine, Mac, who runs Imported Parts Warehouse right here in the Cincinnati area had the things in stock. (IPW's # 513- 874-9881) Through Mac, I bought Semi-loaded caliper which come with pins and anti-rattle clips. He furnished top quality PBR ceramic pads and Brembo rotors. My research in to this still left me with the need of a pad shim kit, caliper bolts and brake lines which would need to come from Toyota.
Bottom line, I save well over haft of what I would pay buying all the parts from Toyota. Now this is more affordable!
10 steps to get er done :
1. Jack up the front of your truck and set it on jack stands. Remove the front wheels.
2. Remove the brake line between the caliper and brake hose. (10 mm brake line wrench)
3. Remove the two bolts behind the caliper with a 17 mm wrench or socket. Remove the caliper assembly.
4. Slide the rotor off the hub. This might require some force, like beating it off with a hammer in this case your definitely replacing it.
5. Set the new caliper up against the backing plate, lining it up with the mounting bolt holes. Outline around the caliper, top and bottom with silver marker. You'll see that only about a haft inch needs to be trimmed on each side. Trim it back with a tin snips and then paint the bare edge with black paint.
6. Coat the hub lightly with silicone brake grease. This will prevent the rotor from rusting in place. Install the rotor. (Use a few lug nut to hold it in place)
7. Install the caliper using the new bolts. You must use new bolts as the old ones are longer and could touch the rotor. Make sure your bleeder screw is at the top!
8. Install the new pads, shims and hardware just as was on the old caliper.
9. Bleed the brakes and your done. Oh repeat on the other side! Now your done
10. Be sure to torque the wheels to prevent a possible rotor warpage.
How It Turned out:
I never like the "feel" of the brakes on this truck and acutely I was getting used to it. But after having to turn the rotors twice to eliminate a bad shake during off highway stops, I new this would need to be done. Now after a few days of driving it with the bigger brake calipers I can say the pedal feel is a lot better. We have yet to see if the reoccurring brake shake is gone for good.
Other things you might need to know:
Parts Sources Used in this swap
Imported Parts Warehouse 9321-A SewardRd. Fairfield Ohio, 513-874-9881, Mac@macsparts.com
Brembo Rotors IPW part #0832821
PBR Ceramic pads IPW part #105.09760
Semi-Loader Calipers RH IPW part #141.44231 LH IPW part #141.44232

Local Toyota Dealer
Brake Line Toyota part #473150C020
Brake Line Toyota part #473180C020
Bolts 4 needed Toyota part #9008010298
Shim Kits Toyota part #0494535080

Torques: Brake caliper bolts 90 Lb-ft
Brake line nuts 11Lb-ft
Wheels lug nuts 83 lb.ft

Tools needed: 17mm socket and ratchet, 10mm line wrench, tin snips or an abrasive cut-off wheel, Sharpie (Metalic Silver works best)
Other matirials: Black spray paint, Silicone brake grease, brake fluid

[LGL002]

Great description and how to. I'm sure many members will be able to upgrade seamlessly using your information.

Larry

[kymatt]

Great post!

Since I'll be in Colerain (actually NCH) this weekend refilling my dart supplies, I'll be sure to stop by our place so that you can work on my truck!

Seriously, I just bought my 3rd set of rotors for my 02. The first ones lasted about 70k with two turns. The second set is now shot (at about 40k). I'm not going to bother turning them because they are cheap rotors to begin with (Carquest, got them free). I went to Pep Boys and bought some Raybestos PG Plus and ceramic pads. I was thinking I'll give these a shot since I've heard very good things. $180 for two rotors + pads (out the door).

I've never done a brake job before but I'm determined to give these a shot. My only worry is bleeding the brake lines. The rest of it seems to be just loosening and retightening bolts.

[Just_Me69]

And BTW, you can sell your old calipers to all of those 3rd gen 4runner owners that want to upgrade their brakes. Being one of these people, We started out with even smaller brakes than you. So please, help out your fellow Toyota owner. It's another way to get some coin in your pocket to offset the cost as well.


Justin

[MEvang]

Justin,
That great to know. My originals have lest the a year on them since a complete rebuild with all factory parts. New Toyota pad and hardware. Drop me a privet email if your interested.
Mike

[strongarmtundra]

ther things you might need to know:
Parts Sources Used in this swap
Imported Parts Warehouse 9321-A SewardRd. Fairfield Ohio, 513-874-9881, Mac@macsparts.com
Brembo Rotors IPW part #0832821
PBR Ceramic pads IPW part #105.09760
Semi-Loader Calipers RH IPW part #141.44231 LH IPW part #141.44232

Local Toyota Dealer
Brake Line Toyota part #473150C020
Brake Line Toyota part #473180C020
Bolts 4 needed Toyota part #9008010298
Shim Kits Toyota part #0494535080

On this list, what is the difference from fully loaded to Semi-loader Calipers? Do you need the Brake lines from Toyota?
What was the total cost for the parts above?
I plan to have my local mech to the TSB. Im going to order all the parts needed however.
thanks for the post...

[longwoodklon]

Semi loaded just means it doesn't include the pads, so you have a choice of what pads you want to use. At least that is my understanding. After 4 years of crappy brakes, I'm about ready to try this. Great Info. here.
/Mike

[MEvang]

You could probably get by without the brake lines if yours are in real good condition. You will need to re-bend them slightly. Longwoodklon is right semi loaded comes with the hardware and not the pads. The total job, I had just under $500.00 in it.
As an update, I'm not real happy with the PBR Ceramic pads, dusting is terrible with these pads. This is my only complaint but I will most likely switch to Toyota pads.
Mike

[strongarmtundra]

my current pads only have around 1,000 miles of driving, if that. I guess I can use my current Ceramic pads for the job. I looked a little more into the brake lines, and I feel I will have them changed also use to have new .
I also plan to have a new timming belt and water pump put (im at 88,000) in at the same time, so my cost will be higher, but worth it. I would like to keep this truck for many years to come.
MEvang, I think I will call you contact above to check price and parts, since you have all the ID #'s listed...
Thanks for the help, as always this site is great.

[strongarmtundra]

Well I had the TSB completed yesterday on my 2001 2WD. I use the contact for parts MEvang used on this post. Semi-loaded capilers 2 New Toyota factory Brake Lines 2 New Brembo Rotors (the old ones were not that bad, a little warped) New Bendix C pads Shim kit New Bolts for Capilers. I have had a brake noise since last Nov, after I replaced the pads on the old Caplilers. So far the feel on the TSB upgrade is great. Better brakeing power, cut out the varibation I was feeling (however I have not complete a hard stop yet over 45 mph) and NO BRAKE NOISE. The cost of the upgrade was worth it. Thanks to all the TSB posters. IT gave me all the info I needed in order to complete the TSB. I had my local mech to do the job. It was stright forward as noted in this (upgrade in one hour post). I will keep an update as to how it comes along here in the next little while.

[Tundrav8yamaha]

Nice write up

I had this Tsb done per southeast Toyota. I dam well demanded for the replacement since my old 2000 Tundra had too many issues on this topic and going back to the dealership too many times . I would have hoped Toyota issues a recall on this But they didnt and saved a dime

I'm glad to see many of you are finding out about the Tsb But In my opinion Toyota should have issued a fix on the very start otherwise you are spending something that should be in there area Not yours. I'm glad I have the 2004 Tundra now this truck is a vast improvement over the 2000 Tundra on brakes. For anybody out there looking at getting a Tundra buy a Truck made after 2003 thats when Toyota phased in the New brakes..

[MTL_4runner]

Originally Posted by Just_Me69

And BTW, you can sell your old calipers to all of those 3rd gen 4runner owners that want to upgrade their brakes. Being one of these people, We started out with even smaller brakes than you. So please, help out your fellow Toyota owner. It's another way to get some coin in your pocket to offset the cost as well.


Justin

Ditto on this info.....there are quite a few 3rd gens on YotaTech (classifieds) that are looking for the smaller 199mm SW13E calipers (including myself, same username on YT) so don't be throwing any working calipers out that came off your truck. I know many places will require cores, but there are a few that don't so you can definately finance at least a bit of your upgrade that way and help out some other fellow Toyota owners. Anyway just a heads up on that!

Mike, great writeup on the caliper swap BTW!

[Ray Kane]

I have a 2003 Tundra AC and had the pads change at 28K miles. I kept the part sticker from the box so I know which pads my truck takes. If I give the info off of the sticker can someone tell me if my truck has the new or old brake setup?
314-03-B1 04465-35290

[Tundrav8yamaha]

Originally Posted by Ray Kane

I have a 2003 Tundra AC and had the pads change at 28K miles. I kept the part sticker from the box so I know which pads my truck takes. If I give the info off of the sticker can someone tell me if my truck has the new or old brake setup?
314-03-B1 04465-35290

I can tell from looking at them take a picture on your brakes .

[Ray Kane]

Originally Posted by TUNDRAV8GEORGIA

I can tell from looking at them take a picture on your brakes .

I will try to do it tomorrow - which angle should I take the picture so you can tell?