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Old 07-10-2012, 05:33 PM #1
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The Infamous FROZED UP brake Caliper

Had my OEM front brake calipers replaced by Toyota at 142K miles, they were severely corroded, once replaced....all was good. Within the last 5K miles....I've noticed that every time I brake, it pulls hard left. Put the Runner on the lift today, pulled the right side tire/rim and tested the pistons....and to my SU-Prise.....all frozed up---AGAIN! I now have 165K on them and will AGAIN replace them with a non-OEM replacement. Any suggestions???
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Old 07-10-2012, 05:41 PM #2
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so you got 142K on the first set and 165K on the second set ?
are you in a winter salt road area ?

Just curious, how much warranty did Toyota give on the first replacement ?
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Old 07-10-2012, 05:48 PM #3
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Good question: I did not think to go back to them to see what the warranty is on them. I live in the Virginia area...cold, wet, some snow. With the original calipers...they lasted 142K miles in the same climate...never out of the Mid-Atlantic area so to speak so they were subjected to the same climate all the time. I only got a short 23K miles on the replacements (both fronts). I will contact Toyota in Maryland (Fitzgeralds) were the work was done. Thanks!
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Old 07-10-2012, 05:59 PM #4
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I've only had frozen calipers, never had FROZED UP ones...

Ahhh, I kid, I kid. Anyways I replaced mine with NAPA re-man units and they have been holding up well. They come painted black and are about 115/ea. I believe they have a lifetime warranty also.

That being said, I think there are cheaper Duralast calipers available at Autozone that also come with a lifetime warranty.

Edit: Flushing your brake fluid is probably also a good idea. Old brake fluid typically has extra water in it, which can lead to premature corrosion of the piston (hence the sticking/freezing).
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Old 07-10-2012, 07:03 PM #5
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All good ideas. I went up online and went to the Toyota site where you can plug in your VIN, create an account and you can see all your service work. I also spoke to the dealership and found out that I am 3 months outside the "warranty" that they provide when you get work done with them. Sent an email to the service manager and will follow up live with him to see what help they can lend. I like the NAPA idea...lifetime warranty! Thanks!
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Old 07-11-2012, 02:14 PM #6
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UPDATE: The dealership said bring it back in....they will look at it and then go to bat for me with Toyota if it is determined that it is in fact "all frozed up" So...stay tuned!
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Old 07-11-2012, 02:19 PM #7
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good luck, stay firm and polite
originals last 140K and repairs last 20K - not good
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Old 07-11-2012, 03:27 PM #8
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Wow, hate to hear this. Good luck fighting with Toyota to get replacements.
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Old 07-11-2012, 04:41 PM #9
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Natevans65 I also live in va I work at a dealership and what I've noticed is when you change calipers you should change the brake fluid as it is hydroscopic and causes caliper pistons to rust internally
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Old 07-11-2012, 05:50 PM #10
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So, I had a similar problem with mine. I had to replace my cv shaft. I'm getting the second one done on Monday, because I'm getting the same problem on the right side now. When you break the car will pull in one direction.
Does it feel like the tire is unbalanced, or like abs is kicking in when you break at all?
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Old 07-12-2012, 02:25 PM #11
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Is this typically only on the front calipers or all 4 wheels?

I have been hearing of this more and more lately. At 140K miles on a 2003 4Runner that came from Colorado, I feel like I am on borrowed time. I did replace the pads and rotors for the first time in the vehicles life within the last year and the calipers compressed just fine.
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Old 07-13-2012, 11:35 AM #12
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Update #2: Dealership said...YEP...they are sticking and SORRY...Toyota will not anty up to help with calipers freezing up with only 24K miles on them. I put in a call to the Toyota Customer Service Center to lodge a case and supposedly I will hear back on the ruling within 3 business days. I am supposed to hear how the mid-Atlantic Toyota Service Center Rep rules on this. I asked the service center rep do I get a chance to speak with them and was told....NO...the dealership will call you back once they have their discussion first and then you will get the ruling. When I picked up the truck this morning and mentioned the infamous brake caliper issues with 4Runners to the General Service Manager at Fitzgerald's....he looked dumb founded and had never heard of 4Runners having this issue. Riiiiiiiiiight......Any who, I can understand that perhaps around 70-80-90K miles they might start to have issues...but at 24K miles that was just serviced a year ago??? Come on.....

Yes...when I did the brake replacement, I drained and filled the brake system with new fluid....so during this past 24K miles I have had fresh fluid in the system. It's a synthetic Amsoil brake fluid that is found at this link..

https://www.amsoil.com/storefront/bf3.aspx

More to come!
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Old 07-13-2012, 09:15 PM #13
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This is what I found after removing the right front Caliper from My 2004 Toyota 4Runner . One of the pistons was frozen (rust) outside of the fluid seal. It looks like the rubber boot did not keep the water out. I replaced it with a NAPA re-man Caliper. The left front I rebuilt with a Seal Kit from Toyota. They also sell the pistons.
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The Infamous FROZED UP brake Caliper-4runner-brake-caliper-ball-joint-005-jpg  The Infamous FROZED UP brake Caliper-4runner-brake-caliper-ball-joint-006-jpg  The Infamous FROZED UP brake Caliper-4runner-brake-caliper-ball-joint-007-jpg 
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Old 08-08-2012, 01:36 PM #14
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Piston

Do you happen to remember the price on these items? How hard was it to remove the piston? Did you need a tool, or did they just come out?

I have this symptom where when I apply my brakes, I hear a clank sound from the right front, then the left front. It's almost as if the pistons are engaging slowly... maybe they need more pressure now to move due to rust, etc...

PS: I live in the Chicago area, and I only have 57K on my 2008 limited.
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Old 03-11-2014, 05:49 AM #15
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anyone else have this issue lately?
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