1997 Toyota T100 Front Brake Rotor Removal

The 1997 Toyota T-100 was equipped with a 2.7-liter four-cylinder engine and two-wheel drive in the base model. A 3.4-liter V-6 was available as an upgrade, as was four-wheel drive. When you replace the rotors on the T-100, you should replace the brake pads as well. Old brake pads will ruin the new rotors much faster. The 1997 T-100 has two styles of brake calipers: PD60 and PD66 types. The replacement procedures for the pads is different for the two types of caliper.

Instructions

Rotor Replacement

1

Loosen the front wheel lug nuts with a tire iron. Raise the front of the truck with a jack, and place jack stands beneath the front frame. Lower the truck onto the stands. Remove the wheel lug nuts completely, then remove both front wheels from the truck.

2

Remove the caliper bolts with a ratchet and socket. Remove the caliper from the brake assembly, using a pry bar if necessary. Insert the pry bar between the inboard and outboard brake pad, and pry the inboard brake pad toward the rear of the caliper. Continue prying until the caliper piston is completely compressed into the caliper. Hang the caliper assembly from the front coil spring, with a metal clothes hanger or rod.

3

Remove the caliper mounting bracket bolts with a 1/2-inch-drive ratchet and socket. Remove the bracket from the brake assembly. Slide the rotor off of the wheel hub by hand.

4

Install the new brake rotor onto the wheel hub. Spin a lug nut onto one of the lug stems, against the face of the rotor, to hold it in place. Install the caliper bracket over the rotor and onto the steering knuckle. Install and tighten the caliper bracket bolts to 80 foot-pounds, with a 1/2-inch-drive torque wrench and socket. Thoroughly spray the front and back sides of the new rotor with aerosol brake cleaner. Remove all of the factory installed anti-rust oil from the rotor with the spray.

5

Repeat Steps 2 through 4 to replace the rotor on the second side of the truck. Proceed to one of the following sections, based upon which caliper (PD60 or PD66) your T100 is equipped with. The instructions for pad removal and replacement are different.

Caliper Type PD 60

6

Remove the brake pads and shims from the caliper, if they did not release during caliper removal. Install new brake pads onto the caliper bracket.

7

Lubricate the metal backing plates of each pad with a thin layer of caliper grease.

8

Install the compressed caliper over the pads and new rotor. Install and tighten the caliper bolts to 24 foot-pounds, with a 1/2-inch drive torque wrench and socket.

9

Repeat Steps 1 through 3 of this section to replace the pads and install the caliper, on the second side of the T100. Remove the single lug nut from the faces of each rotor. Install the front wheels and tighten them snug with a tire iron. Raise the truck off of the jack stands, and remove the stands from beneath the truck. Lower the truck to the ground and tighten the lug nuts to 80 foot-pounds, with your torque wrench and socket.

10

Sit in the driver's seat of the truck and pump the brake pedal slowly, 10 to 15 times. If the brake pedal does not stiffen after five or six pumps, stop pumping the brakes and bleed the front brake system.

Caliper Type PD66

11

Remove the two-"V"-shaped anti rattle clips from the PD66 caliper with a pair of pliers. Pull the brake pads and anti-squeal shims out of the caliper.

12

Install new brake pads and new brake shims into the caliper. The large shim goes on the outboard pad, while the circular shaped shim goes between the inboard pad and caliper piston. Install the "V" shaped anti-rattle clips onto the caliper. Tap the clips in place with a small hammer if necessary. Lubricate the exposed outside shim plate with a light coating of caliper grease.

13

Install the separate brake wear indicators -- the small "L" brackets -- onto the caliper bracket. One indicator goes on the outboard side of the bracket, and the other goes on the inboard side. See the attached diagram in the Reference section. Install the caliper onto the brake assembly, and tighten the caliper bolts to 80 foot-pounds of torque. Remove the single lug nut from the face of the rotor.

14

Repeat Steps 1 through 3 to complete the pad replacement on the second side of the T-100. Install the front wheels and tighten them snug with a tire iron. Raise the truck off of the jack stands, and remove the stands from beneath the truck. Tighten the lug nuts to 80 foot-pounds with a 1/2-inch-drive torque wrench and socket.

15

Sit in the driver's seat of the truck and pump the brake pedal slowly, 10 to 15 times. If the brake pedal does not stiffen after five to six pumps, stop pumping the brakes and bleed the front brake system.