2004 4runner - seized brake calipers?
- Thread starter ollie
- Start date
TechWrench
Senior Member
yabedude said:
With the number of reports of inner lower piston seizing on the 4 piston calipers, I would think there has to be a basic system or design flaw causing it. I haven't done an 'autopsy' on one yet, but if corrosion is forming between the piston and caliper cylinder causing it to seize, it would depend on which side of the piston 'O' ring seal the corrosion is found to get some idea as to why it is happening. If the corrosion is located on the outer side of the 'O' ring, then I would suspect dust boot failiure, or a lot of water being forced into it from tire spray. But, if the corrosion is found on the inside of the 'O' ring, then the corrosion has to be caused by water or some other comtaminate in the brake fluid, collecting in that lower part of the caliper fluid chamber.
I intend to rebuild or replace my front calipers this summer, so unless someone else does it first, I will see what I can learn then.
V8Limited4wd
New member
would this be covered under my toyota platinum warranty? i have 37k miles on the brakes right now so im hoping that the caliper hasnt seized yet.
TechWrench
Senior Member
V8Limited4wd said:
Not sure, you would have to read the fine print in the paperwork. In most cases, brake wear is not covered, unless it is caused by an abnormal part failure. You would have to be able to convince the dealership that the caliper failure was abnormal.
big04runner
Member
seized caliper
I have a 2004 SR5 V6 and at just over 68,000 miles, my brakes started feeling different. While replacing the pads yesterday, the driver side went fine (very easy job). However, I too have the seized caliper problem on the passenger side lower inside piston. That thing is stuck!
Luckily I purchased an extended warranty (Platinum) from Shaun a couple years ago on this forum and the caliper will be replaced under warranty next week by my local Toyota dealership. I just wonder how much longer the driver side will hold up. Guess I have a year and a half left on my warranty to find out!
Update: So I felt dumb. I went to the dealership, got the rental car and came home. A few hours later I got a call saying that everything was working fine and they couldn't find any problems. They went ahead and threw my new replacement pads in for me since they already had it apart. So, no replacement after all. Guess I should have tried harder to get that thing unstuck. But I tell ya, I couldn't get that thing to budge at all!
I have a 2004 SR5 V6 and at just over 68,000 miles, my brakes started feeling different. While replacing the pads yesterday, the driver side went fine (very easy job). However, I too have the seized caliper problem on the passenger side lower inside piston. That thing is stuck!
Luckily I purchased an extended warranty (Platinum) from Shaun a couple years ago on this forum and the caliper will be replaced under warranty next week by my local Toyota dealership. I just wonder how much longer the driver side will hold up. Guess I have a year and a half left on my warranty to find out!
Update: So I felt dumb. I went to the dealership, got the rental car and came home. A few hours later I got a call saying that everything was working fine and they couldn't find any problems. They went ahead and threw my new replacement pads in for me since they already had it apart. So, no replacement after all. Guess I should have tried harder to get that thing unstuck. But I tell ya, I couldn't get that thing to budge at all!
Last edited:
So I'm updating this original post as our truck now needs front brakes again and guess what? More seized calipers! Good times, so much for that "updated" design, Toyota. I guess I should be thankful only that it is only one calper this time...also the truck has only gone another 30,000 miles (first happened at 60,000 kms and now it has 113,000 kms). Sounds like it dragged enough to hose the rotor, wasn't making any noise or pulling either. So the lesson learned is calipers are a regular replacement part on a gen 4 4runner. I know all vehicles have some issues but this is pretty weak, if you ask me. We are preparing to order a new 2010 Gen 5 limited as well and will go ahead but I really hope this issue has been resolved in the new truck.
I have an '04 limited with manual 4 WD. Both lower front pistons were found seized at about 40K, and now at least one of the rebuilts I installed is now also seized. Appears to be a design defect. If doing this yourself be careful to match the casting numbers on the calipers.
cali_axela
New member
Yikes... was planning on doing the brakes on my 04 w/ 56k miles myself and assumed it'd be cake... now you guys have me worried about that pesky lower piston :frisky:
Does this happen on all models? I have a Sport, which I believe has larger front brakes. Is it only the rotors which are larger, or do I have a different part # caliper than other models as well?
Does this happen on all models? I have a Sport, which I believe has larger front brakes. Is it only the rotors which are larger, or do I have a different part # caliper than other models as well?
Kmvreter
New member
Forgot to update this.
My experience so far is doing the drivers side twice and the passenger side once. See the link in my signature to get to the writeup.
Yes, it happens on the Sport with the bigger calipers. It's definitely a common issue, but at least it's an easy fix. You can purchase remanufactured calipers at just about any auto parts store and they aren't too expensive. Keep in mind also that those remanufactured calipers are original Toyota parts.
There are three different casting numbers on the calipers. If you find a frozen piston on yours, just look for the casting number and make sure you replace it with the matching number. If you don't, then the brake line will not match up perfectly with the caliper.
KB084RUNNER
New member
I rotate my tires every 5000 miles and clean the brakes while the tires are off with some brake cleaner. This seems to keep the corrosion to a minimum. Another question: Are you guys opening the bleeder on the caliper when you attempt to retract the pistons? If not, give that a try as it makes it much easier because you are not fighting the system hydraulic pressure and you don't force the contaminated brake fluid from the caliper back up into the system.
KB084RUNNER
New member
BTW, you can get a remanufactured pre-assembled raybestos caliper & pads at rock-auto online for $100 per wheel. There usually a $75 core charge but you get that back when you return the old calipers. If you check on the BITOG website they usually post the 5% Rock auto discount code so you should be able to get all 4 calipers & pads for about $400 plus shipping.
So, those of you that are getting quotes over $1000 :wow2: might consider looking elsewhere. Just sayin.
So, those of you that are getting quotes over $1000 :wow2: might consider looking elsewhere. Just sayin.
Hi,
I have a 2003 V8 Sport and changed 3 out of 4 calipers. Today the Passenger-side rear froze again, which was changed about 3 years ago. This is killing me!!
Hello,
I don't know why toyota won't have a recall on these damn calipers. I've had 3 out 4 calipers changed. Today I'm having the Passenger-side rear changed again. This is killing me!!
While reading up on my low gas mileage (around 12 MPG), someone had posted about checking for a seized caliper. Today when I got to work I used a temp laser to check the temps of the front calipers. The driver front which I think might have a problem was about 15deg or so hotter. What prompted me to take the reading was while I was checking my tire pressure the other day I noticed that the driver front rotor didn't seem to have the same (smooth) wear as the pass front. Does this seem like the typical symptom(s) for a caliper that is bad / going bad ? Other then visual inspection, braking appears to be "normal".
Jeff4runner
New member
It could be a siezing piston, or merely there isnt even distribution of power among the lines. I had trouble with a really spongy brake, and bad pad wear, so I did a complete front brake job, and flushed the entire brake fluid system (6-year old fluid on a 2004). This made a very noticeable difference in that my pads bit down very fast (pushing pedal 1/16 of the way), and it had very fast braking response. For those with problems of the front caliper siezing, try doing a flid flush every two years. Brake fluid could be contaminated with water, or anything else.
My record is twice on front drivers side and once on front passenger side. Luckily the first pair were under warranty. I noticed in the parts for the 5th Gen there is a "spray shield" mentioned- I wonder if they introduced something to reduce the amount of tire spray making it's way up there? Can anyone who knew the 4th Gen brakes well and now has a 5th Gen tell if there has been any design change? I seriously think they should an item for "Change front calipers" in the mtce schedule. They do now schedule brake servicing and flushes on the 5th Gen I noticed (although now there appears to be no scheduled maintenance on the diffs, TC and tranny - perhaps that's where they plan to make money this time)
For the record I have had brake flushes and regular servicing of the sliders etc and it still happens. It's as much a function of weather conditions and salt on the road as anything else I believe.
For the record I have had brake flushes and regular servicing of the sliders etc and it still happens. It's as much a function of weather conditions and salt on the road as anything else I believe.
Bossman
Senior Member
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.
I have contacted Toyota Canada to lodge my complaint, and urge fellow T4R owners in Canada to do the same. Here is the link:
https://www.toyota.ca/toyota/en/sec...j2J9sSHJDYCziDiCPUM&woInstanceId=31&locale=en
For us Canadian 4th Gen T4R owners, you can also lodge your complaint with Transport Canada as a safety concern - check this link:
https://wwwapps.tc.gc.ca/Saf-Sec-Sur/7/PCDB-BDPP/fc-cp.aspx?lang=eng
A definite safety issue in my mind - having brake calipers seize that might effect safe braking should be properly addressed by Toyota.
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.
I have contacted Toyota Canada to lodge my complaint, and urge fellow T4R owners in Canada to do the same. Here is the link:
https://www.toyota.ca/toyota/en/sec...j2J9sSHJDYCziDiCPUM&woInstanceId=31&locale=en
For us Canadian 4th Gen T4R owners, you can also lodge your complaint with Transport Canada as a safety concern - check this link:
https://wwwapps.tc.gc.ca/Saf-Sec-Sur/7/PCDB-BDPP/fc-cp.aspx?lang=eng
A definite safety issue in my mind - having brake calipers seize that might effect safe braking should be properly addressed by Toyota.
13,000 kms later...another seized caliper. This is a joke, seriously...including the original calipers this will be caliper number 6. Truck has only ever been serviced by Toyota, 2 year interval brake fluid flushes, etc...we defered replacing this truck last year as my wife still liked it but this the end of the line for me. She doesn't hot dog around town, doesn't tow, rarely does it see snow, this is way out of line...brake pads are still at 70%.
Similar threads
