2004 4runner - seized brake calipers?

[DocMT]

This is an unfortunate issue and one that doesn't seem to have a permanent fix. We're stuck with replacing our calipers with the same flawed design and just waiting for them to seize up again in the future.

Frustrating? Yes. But if that's the ONLY problem I'll ever have with my 4Runner, then I'll certainly live with it. Other than this issue, my 4Runner has been 100% trouble-free in the seven years I've owned it.

 

[Bossman]

I had my left front brake caliper seize in 2009 at 130,000 km. I could smell something burning under the front of my T4R, and upon investigating found the left front wheel extremely hot to the touch. Brake pads were toast, but rotors were salvageable. Expensive repair.

Now in 2011 at 141,000 km the right front caliper has seized. This time it was not noticed until I brought my T4R for its regular oil/filter service. My mechanic was checking the tire pressures with it up on the hoist, and he could not turn the rim freely by hand. Again pads had to be replaced, and rotors machined. Expensive repair.

With the power/torque of the V8, early signs of this issue are easily missed. Simply putting the vehicle in drive and stepping off the brake, the vehicle easily creeps ahead. Vehicles with less torque would not creep, leading to easy diagnosis. By the time most if us recognize a problem, the seized caliper has caused damage to pads and rotors.

I take very good care of my T4R, and follow recommended maintenance service. I also expect a certain amount of wear and tear on certain items. But this seems to be a premature failure of a component due to poor design and/or construction.

Update! November 2015 and 169,800 km and the right caliper has seized again. The brake pedal when depressed was starting to feel soft and spongy. Regular brake services done - most recently 6 months ago at 161,700 km.

Went ahead and replaced both front calipers, rotors and pads.

 

[VertigoPerformance]

I've had 2 - 2003 runners and replaced the callipers numerous times on both.
I had Toyota install after market ones from UAP/NAPA
They have life time warrantees, When they need replacing I do it, take the callipers to Toyota, they have the parts store exchange the part and I reinstall.
It pays to be on good terms with your dealer or any mechanics shop.