How to Remove the Brake Rotor on a 2005 Toyota Sienna

Toyota introduced the Sienna minivan in 1998, to replace the Toyota Previa. The 2005 Toyota Sienna was equipped with a 3.3-liter multi-port fuel injected, DOHC V-6 engine capable of producing 230 horsepower. This van was equipped with the option of two-wheel or four-wheel disc brakes. Replacing the rotors on the 2005 Toyota Sienna is a task that should be performed by someone with prior automotive experience.

Instructions

1

Raise the hood of the Sienna. Check the brake fluid level in the reservoir, located on the driver's side firewall of the engine compartment. Remove the brake fluid with a turkey baster or a bottle siphon if the reservoir is at the "Full" mark. The brake level should be about 1/2-inch below the "Full" mark prior to servicing the brakes.

2

Loosen the front wheel lug nuts with a tire iron. Raise the front of the Sienna with a jack. Place jack stands under the subframe, just inward from the lower control arms. Remove the lug nuts completely, then remove the front wheels from the Sienna.

3

Hold the lower caliper slide pin with an open-end wrench, on the rear of the caliper. The slide pin is on the rear of the caliper, between the caliper and the steering knuckle. Remove the lower caliper mounting bolt with a 3/8-inch-drive ratchet and socket. Remove the upper mounting bolt in this same manner.

4

Pull the caliper free of the brake assembly, and hang the caliper from the front strut spring, using a wire clothes hanger or thin metal rod. Do not let the caliper hang by the rubber hose it is attached to. Remove the outboard anti-squeal clip from the caliper, using a screwdriver if necessary. Remove the outboard brake pad from the caliper.

5

Install a large C-clamp around the inboard brake pad and the rear of the caliper. Slowly tighten the C-clamp to completely compress the caliper piston. Remove the C-clamp when the piston is compressed, then remove the inboard brake pad anti squeal clip and inboard brake pad. Discard the old brake pads completely.

6

Remove the caliper mounting bracket bolts from the back of the steering knuckle with a 1/2-inch-drive breaker bar and socket. Remove the caliper bracket from the Sienna. Remove the brake rotor by pulling it off.

7

Install the new brake rotor. Spin a lug nut onto the lug stud, against the face of the new rotor. Thoroughly coat the new brake rotor with aerosol brake spray. You should use about one-half of a can spraying both sides of one rotor. Install the caliper bracket and bolts, and tighten the bolts to 79 foot-pounds of torque with a torque wrench and socket.

8

Install the new inboard pad into the brake caliper, then install a new anti-squeal clip. Make sure the inboard brake pad has the "L" shaped metal wear indicator on it. Use a screwdriver for installing the clip if needed. Install the outboard brake pad (without "L" shaped indicator) into the caliper. Install the anti-squeal clip onto the outboard brake pad.

9

Remove the caliper slide pins from the back of the brake caliper by hand. Dip the slide pins directly into a tub of caliper grease. Insert the pins back into the rear of the caliper. Dab a thin layer of caliper grease on the exposed backing plate of the outboard brake pad. Install the caliper assembly and pads onto the brake assembly. Insert the caliper mounting bolts and tighten them to 25 foot-pounds with a torque wrench and socket. Remove the single lug nut from the hub.

10

Repeat Steps 2 through 8 to complete the rotor replacement on the second side of the Sienna. Double-check your torque on all of the caliper mounting bracket bolts and caliper bolts. Install the front wheels and snug the lug nuts with the tire iron. Raise the Sienna off of the jack stands, then remove the stands from beneath the van. Lower the van to the ground. Immediately tighten the front wheel lug nuts to 80 foot-pounds with the torque wrench and a socket.

11

Pump the brake pedal slowly and gently, at least 10 to 15 times. The brake pedal should stiffen up and become harder to depress. If the brake pedal is still soft after 5 to 7 pumps, stop pumping and bleed the front brake system.

12

Check the brake fluid level under the hood. Add brake fluid as needed, then tighten the reservoir cap back into place.