15" to 16" wheel upgrade with 16" front disks and calipers

[VA984Runner]

I've had a chronic problem with my 1998 2WD (15" wheels) 4Runner's front brake rotors. Avoiding a few accidents is more than enough to introduce enough axial play in the rotors to develop a pulse in the brakes, which then just gets worse.

I notice that 4Runners with 16" wheels had a front brake rotor which was 3/4" greater in diameter and that the 15" calipers and 16" are also different.

If I understand it correctly, based on Toyota part #'s, I'd have to change the dust shields to the 16" shields, change the rotors to the 16" rotors, change the calipers to the 16" calipers, and then of course the change the wheels, tires, and possibly lug nuts. This is no small job or expense.

My last set of brand new OEM rotors started pulsing only after 10K miles and I don't want to have to pull apart the 4Runner every ten thousand miles. I just tried a new set of NAPA rotors and pads, and the vibration is so severe that I can't drive the vehicle over 40 mph. I'll need to fix the issue immediately.

Even worse, my local Oreilly's won't machine the rotors and can't find another shop to do it. FYI, this vehicle is a workhorse and simply can't stay out of service. It can't be down for more than a weekend.

Has anyone else done this upgrade and produced any good results?

 

[phattyduck]

More likely the issue is uneven pad deposits on the rotor. Better (for your use pattern) pads may help.

As for the upgrade, yes, many have done it.

You will also want to upgrade the rear wheel cylinders to match the larger front brakes while you are at it.

If you have steel wheels, you will need new lug nuts if you go with OEM style alloy wheels. You can use take-offs from any number of Toyota trucks though - 3rd-5th gen 4Runner, FJ Cruiser, 1st-3rd gen Tacoma, 1st gen Tundra, etc. so it doesn't have to be expensive. If you buy from someone who upgraded to aftermarket wheels, they will have their old lug nuts that you may be able to get cheap too (aftermarket wheels generally use cone seat, not the OEM washer style).

You can cut/bend the front dust shields if you don't want the hassle of replacing. No other unexpected items beyond your list will be needed other than the rear wheel cylinders I already mentioned.

I've had the original 15" brakes, 16" brakes and the Tundra upgrade. The 16" brakes are much better and the Tundra brakes seem to be impervious to issues once bled correctly.

-Charlie

 

[VA984Runner]

Any idea if the rotors for the 16" wheels will be more durable?

 

[JBurt]

I'd take a read through this. It is a bulletproof setup

Hard to find Specs, Info & Measurements on 231mm 13WL Tundra Calipers & Rotors