A few weeks back my two summered from the relatively common 'stuck caliper' syndrome, whereby I got a nasty smell of burning pads while driving along, and also found that my car would stick on a down hill slope without using any brakes!

This can be caused by stuck pistons within the caliper(s), and also stuck slider bolts. I had both - but did not realise at the time. There is a caliper rebuild procedure that is reasonably straight forward but can sometimes become difficult if the piston seal has ripped and the caliper bore has become corroded/rusty. So I did it the lazy way and ordered a set of rebuilt (exchange) calipers from Camskill.

Camskill shipped to me in 1day! and packed super well...

_KUNENA_BBCODE_HIDEIMG

I also ordered a set of slider bolts at the same time as they seemed to be quite cheap enough to replace. Camskill stock the genuine Toyota part.

_KUNENA_BBCODE_HIDEIMG

The calipers are zinc coated but it seems that they were done in different batches judging by the colours

_KUNENA_BBCODE_HIDEIMG

Important stamp. Rev1 had smaller brakes/calipers than Rev 2,3,4,5

_KUNENA_BBCODE_HIDEIMG

Nice clean looking pistons and seals in perfect condition

_KUNENA_BBCODE_HIDEIMG

I ran about all over Dublin but could not find anyone that had black caliper paint in stock, so I did a temporary job with some high temp paint until I could get the right stuff...

_KUNENA_BBCODE_HIDEIMG


_KUNENA_BBCODE_HIDEIMG

No problem with colours now :)

_KUNENA_BBCODE_HIDEIMG

_KUNENA_BBCODE_HIDEIMG

The offender! I should have gotten on to this sooner as last time I went through the NCT the car came back with a big difference in braking power from one side to the other. I wanted to do a good job so I chose to replace both sides at the same time.

_KUNENA_BBCODE_HIDEIMG

Unfortunately pictures under the wheel arch are not so easy to get, but basically the caliper is held on via two 14mm bolts and the brake line via a 12mm banjo

_KUNENA_BBCODE_HIDEIMG

After cracking the seal on the brake line bolt, you'll get a run of brake fluid, so be ready with a container

_KUNENA_BBCODE_HIDEIMG

If you're doing this job, might be a handy thing to order new banjo bolts and crush washers. Mine are end of life for sure. Luckilly I landed up getting them to work but would have liked to have new ones..

_KUNENA_BBCODE_HIDEIMG

The old caliper

_KUNENA_BBCODE_HIDEIMG

New caliper for comparison

_KUNENA_BBCODE_HIDEIMG

As you can see the inner pad has taken some amount of punishment compared to the outer pad!

_KUNENA_BBCODE_HIDEIMG

I started with my good side caliper so as to make the 'learning side' that little bit easier for myself. Just when I was doing a test fit of the replacement caliper, I noticed that the thread on the fluid feed was looking a bit iffy :dry:

_KUNENA_BBCODE_HIDEIMG

_KUNENA_BBCODE_HIDEIMG
:angry:

There was no way the banjo would screw in so after some swearing I broke out the old faithful tap and die set

_KUNENA_BBCODE_HIDEIMG

Found the correct thread width

_KUNENA_BBCODE_HIDEIMG

And gave the thread some manual persuation

_KUNENA_BBCODE_HIDEIMG

Andy after a little while - hey presto!

_KUNENA_BBCODE_HIDEIMG

Caliper in place and ready for action :)

_KUNENA_BBCODE_HIDEIMG

_KUNENA_BBCODE_HIDEIMG

While running through this procedure I had found that one of my slide bolts was fully seized in the caliper bracket. I tried forcing it with a breaker bar, but unfortunately the bolt was too far gone and landed up snapping off in the bracket. So with no other option, I bought a new bracket from Toyota. The dust boots that are in the picture are quite important as if they perish, then water gets in to the slide bolt and corrodes it like a B1tch!

_KUNENA_BBCODE_HIDEIMG

Old manky bracket (one that I reused, not the stuffed one)

_KUNENA_BBCODE_HIDEIMG

New versus old (and in this case still intact - well the rubber part anyway) dust seal

_KUNENA_BBCODE_HIDEIMG

In order that I did not want to tackle this job anytime soon, I elected to throw on some anti sieze

_KUNENA_BBCODE_HIDEIMG

_KUNENA_BBCODE_HIDEIMG

I put some copper grease in the bore, then tapped home the new seal (courtesy of a 10mm socket)

_KUNENA_BBCODE_HIDEIMG

Then it was a bit more on the slider pin and in to place!

_KUNENA_BBCODE_HIDEIMG

_KUNENA_BBCODE_HIDEIMG

_KUNENA_BBCODE_HIDEIMG

Then it was a case of moving across the pad clips for the new bracket, and just reassembling the other bracket that I was reusing

_KUNENA_BBCODE_HIDEIMG

All in all I was happy with the outcome, I'll be moving on to do the back brakes in coming weeks... :S

Good job Quandry, nice write up..out of KC's for now.

Nice one Geoff, should loosen up a few more ponies for you.

KC for the write up.

Great write up, KC+1 for you. I would love to seem more of these, even one for basic servicing etc for the likes of me.....!

Punky1968 wrote:
Great write up, KC+1 for you. I would love to seem more of these, even one for basic servicing etc for the likes of me.....!

I should be putting one of them together over the winter. Any questions in the meantime just ask.

great write up!!! this is something i have to do later on too. so, this will come very useful for me. KC +1

great pic too. very detail. i can see all your finger print. now i can use your I.D to buy stuff off the internet.

Great write up Geoff. My calipers are on their way out also. If things go well with the bank man tomorrow I think I'll add these to the build list.

This a great write up, fair play. You sure know what your doing. Explained in great detail and photo's always help..will be a massive help when time comes for mine to be done...Gud job

KC for you

Deadly write up

very good right up

the dust boots are a must on any brake rebuild as there first to perish
great to see the job planned out in front much easier to see what may be needed .

Punky1968 wrote:
Great write up, KC+1 for you. I would love to seem more of these, even one for basic servicing etc for the likes of me.....!

Yeah same here! Just got a letter from the NCT people kindly reminding me to get my NCT, 4 months before it's due, what's that all about! lol

good write up. Actually replaced my own pads and rotors yesterday too. Should have taken some pictures took me a while to figure out that you have to take the caliper off the bridge to pu the springs on easily. i was messing around for an hour tryin to fit two springs and two pads into the caliper in one move

How much did you pay for the replacement caliper and bridge?

KC + 1

AlersNiga wrote:
good write up. Actually replaced my own pads and rotors yesterday too. Should have taken some pictures took me a while to figure out that you have to take the caliper off the bridge to pu the springs on easily. i was messing around for an hour tryin to fit two springs and two pads into the caliper in one move

How much did you pay for the replacement caliper and bridge?

KC + 1

I got the two calipers on an exchange basis from Camskill. They were 100 pounds per side. The bracket I bought new from Toyota for 95 eur. In hindsight I could have got one way cheaper from MR2 Joe but I was a bit pushed for time and Cranleys were able to get me one next day.

Still saving up to do the back

Nice on for the write up Quandry! You've got me out of a hole! Iwent the same road as you with camskill recons. KC 4 u

Glad to have been some help!

Would you believe I am still saving up to do the back ones

Quick question anyone know are the front brake bleed nipples the same as the rear on a 92 rev 2 turbo cos I'm dropping in yellow stuff pads and race fluid so I wanna pick up new nipples before I strip the car down... I can find replacement nipples on camskill but it says brake nipple front and dosnt have a rear option!!!
www.camskill.co.uk/m5b0s604p0/Toyota_MR2...Brakes_-_Other_Parts

3rd last item on the page I just don't wanna end up with 4 front nipples And find out I need a rear to finish the job!!!!


Cheers for any replies
Mick

Only bleed the brakes last week and Toyota being the way they are I would say they are the same.

Edit: Some part numbers for you, I would still say they are the same unit.

Front Part # 47547‑20010

Rear Part # 47547‑22020

That is for a Rev III N/A, what version is yours or PM me your chassis number for an exact part number.

I got your PM and the numbers below are correct for your car from what I can see without the chassis number.

Front Part # 47547‑20010

Rear Part # 47547‑22020

Cheers I'll ring Toyota tomorrow anyway and check price off them sure they can't be that dear... I've used my local dealers few times over the years and they haven't fleeced me that much except for the time I rang looking for t bar seal price.....

Thanks

Cheers I'll ring Toyota tomorrow anyway and check price off them sure they can't be that dear... I've used my local dealers few times over the years and they haven't fleeced me that much except for the time I rang looking for t bar seal price.....

Thanks

if toyota dont know as they mite not tell you as there different part numbers and they dont like mixing and matching i can check off the calipers i have a bit of everything up there ha rev1 to rev3

Yea if u could check it would help me out cos I know toyota are gonna say they don't know if their different

yeh il check them during the the day and let you know later when im back home dude

Any chance ya checked if front and rear bleed nipples are the same got my yellow stuff pads during the week so wanna throw 4 new nipples when I'm putting the good fluid in!!!

Cheers
Mick

sorry ment to write back.yes i tried a rear rev1 turbo nipple in a rev 3 front caliper and vice versa and both were the same in each.