Last Modified: 08-21-2023 6.11:8.1.0 Doc ID: RM100000001JKJC
Model Year Start: 2020 Model: Avalon HV Prod Date Range: [08/2019 -           ]
Title: BRAKE (FRONT): FRONT BRAKE (for 2-Pot Caliper): INSTALLATION; 2020 - 2022 MY Avalon Avalon HV [08/2019 -        ]

INSTALLATION

CAUTION / NOTICE / HINT

NOTICE:

  • Immediately after installing the front disc brake pads, the braking performance may be reduced. Always perform a road test in a safe place while paying attention to the surroundings.
  • After replacing the front disc brake pads, always perform a road test to check the braking performance and check for vibrations.

HINT:

  • Use the same procedure for the RH side and LH side.
  • The following procedure is for the LH side.

PROCEDURE

1. INSTALL FRONT DISC

(a) Align the matchmarks of the front disc and front axle hub sub-assembly, and install the front disc.

NOTICE:

When replacing the front disc with a new one, select the installation position where the front disc has minimal runout.

*a

Matchmark

2. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING

(a) Install the front disc brake cylinder mounting to the steering knuckle with the 2 bolts.

Torque:

107 N·m {1091 kgf·cm, 79 ft·lbf}

3. INSTALL FRONT DISC BRAKE BUSHING DUST BOOT

(a) Apply a light layer of lithium soap base glycol grease to the entire circumference of 2 new front disc brake bushing dust boots.

HINT:

Apply more than 0.3 g (0.01 oz) of lithium soap base glycol grease to each front disc brake bushing dust boot.

Lithium Soap Base Glycol Grease

(b) Install the 2 front disc brake bushing dust boots to the front disc brake cylinder mounting.

4. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN

(a) Apply a light layer of lithium soap base glycol grease to the contact surface of the front disc brake cylinder slide pin (lower side) and a new front disc brake cylinder slide bushing.

Lithium Soap Base Glycol Grease

(b) Install the front disc brake cylinder slide bushing to the front disc brake cylinder slide pin (lower side).

(c) Apply a light layer of lithium soap base glycol grease to the sliding part and the sealing surfaces of the 2 front disc brake cylinder slide pins.

Lithium Soap Base Glycol Grease

(d) Install the 2 front disc brake cylinder slide pins to the front disc brake cylinder mounting.

(e) Push each front disc brake cylinder slide pin into the front disc brake bushing dust boot to engage the pin to the boot.

5. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE

(a) Install the 4 front disc brake pad support plates to the front disc brake cylinder mounting.

NOTICE:

Be sure to install each front disc brake pad support plate in the correct position and direction.

6. INSTALL FRONT DISC BRAKE ANTI-SQUEAL SHIM KIT

Click here 2020 - 2022 MY Avalon Avalon HV [08/2019 -        ]; MAINTENANCE: FRONT DISC BRAKE PAD (for 2-Pot Caliper): INSTALLATION+

7. INSTALL FRONT DISC BRAKE PAD

(a) Install the 2 front disc brake pads to the front disc brake cylinder mounting.

NOTICE:

  • Keep the friction surfaces of the front disc brake pads and front disc free from oil and grease.
  • Install the front disc brake pad so that the front disc brake pad wear indicator plate is mounted on the upper side of the vehicle.

(b) Install the 2 anti-squeal springs to the front disc brake pads.

NOTICE:

  • When replacing the front disc brake pads with new ones, make sure to replace the anti-squeal springs at the same time.
  • Be sure to install the anti-squeal springs into the front disc brake pad installation holes as far as they will go.

8. INSTALL FRONT DISC BRAKE CYLINDER ASSEMBLY

(a) Hold each front disc brake cylinder slide pin and install the front disc brake cylinder assembly to the front disc brake cylinder mounting with the 2 bolts.

Torque:

34.3 N·m {350 kgf·cm, 25 ft·lbf}

NOTICE:

  • Install the front disc brake cylinder assembly while holding both of the front disc brake pads because the anti-squeal springs may fall off the front disc brake pads.
  • Be sure that the anti-squeal springs are installed to the front disc brake pads.

9. CONNECT FRONT FLEXIBLE HOSE

(a) Connect the front flexible hose to the front disc brake cylinder assembly with a new union bolt and a new gasket.

Torque:

29.4 N·m {300 kgf·cm, 22 ft·lbf}

NOTICE:

Install the front flexible hose lock securely into the lock hole in the front disc brake cylinder assembly.

10. BLEED BRAKE LINE

Click here 2019 - 2022 MY Avalon [04/2018 -        ]; BRAKE SYSTEM (OTHER): BRAKE FLUID (for Gasoline Model): BLEEDING

11. INSTALL FRONT WHEEL

Click here 2019 - 2022 MY Avalon Avalon HV [04/2018 -        ]; MAINTENANCE: TIRE AND WHEEL: INSTALLATION+