BRAKE (REAR): REAR BRAKE: INSTALLATION; 2022 - 2024 MY RAV4 RAV4 HV [12/2021

Last Modified: 01-30-2024	6.11:8.1.0	Doc ID: RM1000000021J5A
Model Year Start: 2022	Model: RAV4	Prod Date Range: [12/2021 - ]
Title: BRAKE (REAR): REAR BRAKE: INSTALLATION; 2022 - 2024 MY RAV4 RAV4 HV [12/2021 - ]

INSTALLATION

CAUTION / NOTICE / HINT

NOTICE:

Immediately after installing the 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 rear disc brake pads, the brake pedal may feel soft due to clearance between the rear disc brake pads and rear disc. Depress the brake pedal several times until the brake pedal feels firm.
After replacing the rear disc brake pads, always perform a road test to check the braking performance and check for vibrations.
When removing or installing the rear disc brake cylinder assembly, pushing back the disc brake piston may cause a large clearance between the brake pads and brake disc. When the brake pedal is depressed with a large clearance between the brake pads and the brake disc, DTC C140000 and/or C140A00 related to abnormal brake fluid pressure may be stored. Make sure to clear any DTCs after performing this procedure. (w/o vacuum brake booster)
While the auxiliary battery is connected, even if the ignition switch is off, the brake control system activates when the brake pedal is depressed or any door courtesy switch turns on. Therefore, when servicing the brake system components, do not operate the brake pedal or open/close the doors while the auxiliary battery is connected. (w/o vacuum brake booster)

HINT:

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

PROCEDURE

1. INSTALL REAR DISC

(a) Align the matchmarks of the rear disc and rear axle hub and bearing assembly, and install the rear disc.

NOTICE:

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

Matchmark

2. INSTALL REAR DISC BRAKE CYLINDER MOUNTING

(a) Install the rear disc brake cylinder mounting to the rear axle carrier sub-assembly with the 2 bolts.

Torque:

107 N·m {1091 kgf·cm, 79 ft·lbf}

3. INSTALL REAR DISC BRAKE BUSHING DUST BOOT

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

HINT:

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

Lithium Soap Base Glycol Grease

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

4. INSTALL REAR DISC BRAKE CYLINDER SLIDE PIN

Lithium Soap Base Glycol Grease

(a) Apply a light layer of lithium soap base glycol grease to the contact surface of the rear No. 2 disc brake cylinder slide pin.

(b) Install a new rear disc brake cylinder slide bushing to the rear No. 2 disc brake cylinder slide pin.

Lithium Soap Base Glycol Grease

(c) Apply a light layer of lithium soap base glycol grease to the sliding part and the sealing surfaces of the rear No. 1 disc brake cylinder slide pin and rear No. 2 disc brake cylinder slide pin.

(d) Install the rear No. 1 disc brake cylinder slide pin and rear No. 2 disc brake cylinder slide pin to the rear disc brake cylinder mounting.

*1	Rear No. 1 Disc Brake Cylinder Slide Pin
*2	Rear No. 2 Disc Brake Cylinder Slide Pin

(e) Push the rear No. 1 disc brake cylinder slide pin and rear No. 2 disc brake cylinder slide pin into each rear disc brake bushing dust boot to engage the pins to the boots.

5. INSTALL REAR DISC BRAKE PAD SUPPORT PLATE

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

NOTICE:

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

6. INSTALL REAR DISC BRAKE ANTI-SQUEAL SHIM

Click here

7. INSTALL REAR DISC BRAKE PAD

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

NOTICE:

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

HINT:

If the rear disc brake pad has an identification mark, be sure to confirm the installation location.

*a	Inner Side (Orange)
*b	Outer Side (Yellow green)

8. INSTALL REAR DISC BRAKE CYLINDER ASSEMBLY

(a) Hold the 2 rear disc brake cylinder slide pins, and install the rear disc brake cylinder assembly to the rear disc brake cylinder mounting with the 2 new bolts in the order shown in the illustration.

Torque:

34.3 N·m {350 kgf·cm, 25 ft·lbf}

*a	Turn
*b	Hold

9. INSTALL PARKING BRAKE ACTUATOR ASSEMBLY LH

Click here

10. CONNECT NO. 2 PARKING BRAKE WIRE ASSEMBLY

Click here

11. CONNECT REAR FLEXIBLE HOSE LH

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

Torque:

29 N·m {296 kgf·cm, 21 ft·lbf}

NOTICE:

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

12. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL (w/o Vacuum Brake Booster)

(a) Connect the reservoir level switch connector.

(b) Connect the cable to the negative (-) auxiliary battery terminal.

Click here

(d) Depress the brake pedal and release it.

(e) Clear the DTCs.

Click here

13. BLEED BRAKE LINE

w/ Vacuum Brake Booster:
Click here
w/o Vacuum Brake Booster:
Click here

14. BLEED REAR DISC BRAKE CYLINDER ASSEMBLY (w/ Vacuum Brake Booster)

CAUTION:

If the rear disc brake cylinder assembly has been disassembled, perform air bleeding for the rear disc brake cylinder.

NOTICE:

Perform air bleeding while maintaining the brake fluid level between the MAX and MIN lines on the brake fluid reservoir.
Do not allow brake fluid to contact any painted surface. If brake fluid leaks onto any painted surface, immediately wash it off.

HINT:

Use the same procedure for the RH and LH sides, except where indicated.
The following procedure is for the LH side.
While performing air bleeding of the rear disc brake assembly, the bolt can be reused during the bleeding procedure. After air bleeding is complete, replace the bolt with a new one.

(a) Perform the procedure to enter rear disc brake pad replacement mode 5 times.

Click here

(b) Disconnect the No. 2 parking brake wire assembly connector from the parking brake actuator assembly LH.

(c) Hold the 2 rear disc brake cylinder slide pins and remove the 2 bolts and separate the rear disc brake cylinder assembly from the rear disc brake cylinder mounting.(*1)

NOTICE:

Keep the rear no. 2 disc brake cylinder slide pin free of foreign matter.

*a	Turn
*b	Hold

(d) Hold the rear disc brake cylinder assembly horizontally, then tilt it 45° toward the bleeder plug side as shown in the illustration.(*2)

(e) Temporarily install the rear disc brake cylinder assembly with the 2 bolts.(*3)

*a	Turn
*b	Hold

(f) Remove the center cowl top ventilator louver.

Click here

(g) Remove the brake master cylinder reservoir filler cap.

Click here

(h) Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.

NOTICE:

Make sure that there is sufficient brake fluid in the reservoir.
If brake fluid leaks onto any painted surface, immediately wash it off.
Do not remove the filter from the brake master cylinder reservoir and be sure to fill the brake master cylinder reservoir with new brake fluid to avoid any potential contamination of the brake system. Contamination, for example by dirt particles or mineral oil, could lead to functional brake problems.

(i) Depress the brake pedal several times, and then loosen the bleeder plug with the pedal depressed.(*4)

(j) When fluid stops coming out, tighten the bleeder plug and release the brake pedal.(*5)

(k) Repeat steps (*1) through (*5) 3 times.

NOTICE:

If there is still air in the system after performing steps (*1) through (*5) 3 times, repeat the steps (*1) through (*5) until the air has been bled.

(l) Tighten the bleeder plug completely.

Torque:

8.3 N·m {85 kgf·cm, 73 in·lbf}

(m) Install the rear disc brake cylinder assembly with a 2 new bolts.

Torque:

34.3 N·m {350 kgf·cm, 25 ft·lbf}

(n) Connect the No. 2 parking brake wire assembly connector to the parking brake actuator assembly LH.

(o) Inspect for brake fluid leaks.

(p) Inspect the brake fluid level in the reservoir.

Click here

(q) Install the brake master cylinder reservoir filler cap assembly.

Click here

(r) Install the center cowl top ventilator louver.

Click here

15. BLEED REAR DISC BRAKE CYLINDER ASSEMBLY (w/o Vacuum Brake Booster)

CAUTION:

If the rear disc brake cylinder assembly has been disassembled, perform air bleeding for the rear disc brake cylinder assembly.

HINT:

While performing air bleeding of the rear disc brake cylinder assembly, the bolts can be reused during the bleeding procedure. After air bleeding is complete, replace the bolts with new ones.

(a) Perform the procedure to enter rear disc brake pad replacement mode 5 times.

Click here

(b) Disconnect the No. 2 parking brake wire assembly connector from the parking brake actuator assembly LH.

(1) Disengage the 3 hooks and separate the hood to cowl top seal from the cowl top ventilator louver sub-assembly.

(2) Disengage the 2 claws and 2 guides to remove the center cowl top ventilator louver from the cowl top ventilator louver sub-assembly.

(d) Remove the brake master cylinder reservoir filler cap assembly.

(e) Force air within the rear disc brake cylinder assembly to accumulate at the rear disc brake bleeder plug.(*1)

(1) Disable brake control.

Click here

(2) Disconnect the No. 2 parking brake wire assembly connector.

Click here

(3) Hold the 2 rear disc brake cylinder slide pins and remove the 2 bolts and separate the rear disc brake cylinder assembly from the rear disc brake cylinder mounting.

*a	Turn
*b	Hold

(4) Hold the rear disc brake cylinder assembly horizontally, then tilt it 45° toward the bleeder plug side as shown in the illustration.

(5) Temporarily install the rear disc brake cylinder assembly to the rear disc brake cylinder mounting with the 2 bolts.

(6) Connect the No. 2 parking brake wire assembly connector.

Click here

(7) Connect the reservoir level switch connector.

(8) Connect the cable to the negative (-) auxiliary battery terminal.

Click here

(9) Turn the ignition switch to ON (READY).

(10) Depress the brake pedal and release it.

(11) Apply the parking brake.

(f) Enter ECB (Electronically Controlled Brake system) Deactivate Mode.(*2)

NOTICE:

Performing the following procedure enters ECB (Electronically Controlled Brake system) Deactivate Mode without using the GTS.
ECB (Electronically Controlled Brake system) Deactivate Mode allows the brake lines to be bled without using the GTS.
The brake warning light blinks (yellow) to indicate that ECB (Electronically Controlled Brake system) Deactivate Mode is selected.
Be sure to confirm that the brake warning light is blinking (yellow) throughout the brake line bleeding procedure.

If any of the following conditions are met, ECB (Electronically Controlled Brake system) Deactivate Mode is canceled and the brake warning light (yellow) turns off. Do not allow ECB (Electronically Controlled Brake system) Deactivate Mode to be canceled while bleeding the brake lines or DTCs may be stored.

The shift lever is moved from P to any other position.

The ignition switch is turned to ON (READY).

The ignition switch is turned off.

The parking brake is released.

The vehicle speed is more than 0 km/h (0 mph).

Do not rotate any brake disc while ECB (Electronically Controlled Brake system) Deactivate Mode is selected.
Although the brake warning light (yellow) will blink and a buzzer will sound while performing brake line bleeding, this is not a malfunction.

(1) Perform the procedure listed below within 1 minute.

Turn the ignition switch to ON with the shift lever in P and parking brake applied.
Move the shift lever to N and then depress the brake pedal more than 8 times within 5 seconds.
Move the shift lever to P and then depress the brake pedal more than 8 times within 5 seconds.
Move the shift lever to N and then depress the brake pedal more than 8 times within 5 seconds.
Move the shift lever to P.

(2) Check that the brake warning light is blinking (yellow).

*a	Brake Warning Light (Yellow)

(g) Bleed the brake line.(*3)

(1) Remove the brake master cylinder reservoir filler cap assembly.

(2) Remove the rear disc brake bleeder plug cap.

(3) Connect a vinyl tube to the rear disc brake bleeder plug.

(4) Add brake fluid to the reservoir until the fluid level is between the MAX and MIN lines on the brake fluid reservoir.(*a)

(5) Depress the brake pedal several times with approximately 1 second between each depression, and then loosen the bleeder plug with the pedal depressed.(*b)

(6) When brake fluid stops coming out, tighten the bleeder plug and then release the brake pedal for 1 second or more.(*c)

HINT:

When the brake pedal is released, the piston inside the master cylinder may take longer than the brake pedal to return to its original position. Therefore, make sure to wait for 1 second or more between each depression of the brake pedal.

(7) Repeat steps (*a) through (*c) until there are no signs of air in the brake fluid.

(8) Release the parking brake.

(h) Repeat steps (*1) through (*3) 3 times.

NOTICE:

If there is still air in the system after performing steps (*1) through (*3) 3 times, repeat the steps (*1) through (*3) until the air has been bled.

(i) Tighten the rear disc brake bleeder plug completely.

Torque:

8.3 N·m {85 kgf·cm, 73 in·lbf}

(j) Install the rear disc brake bleeder plug cap to the rear disc brake bleeder plug.

(k) Hold the 2 rear disc brake cylinder slide pins, and install the rear disc brake cylinder assembly to the rear disc brake cylinder mounting with 2 new bolts.

Torque:

34.3 N·m {350 kgf·cm, 25 ft·lbf}

(l) Inspect for brake fluid leaks.

(m) Adjust the brake fluid level in the reservoir.

Click here

(n) Install the brake master cylinder reservoir filler cap assembly.

(o) Install the center cowl top ventilator louver.

(1) Engage the 2 claws and 2 guides to install the center cowl top ventilator louver from the cowl top ventilator louver sub-assembly.

(2) Engage the 3 hooks and install the hood to cowl top seal from the cowl top ventilator louver sub-assembly.

(p) Turn the ignition switch off.

(q) Clear the DTCs.

Click here

16. INSTALL REAR WHEEL

Click here

17. NORMAL CONDITION RECOVERY

w/ Vacuum Brake Booster:
Click here
w/o Vacuum Brake Booster:
Click here