Calipers Frozen? You bet!

[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.

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.

 

[truckmike26]

It's an inherent problem of the floating, two- and four-piston caliper design. Corvette owners suffer with this, as do older F350 4x4 Ford owners.

 

[Eastcoastrunner]

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.

this is the response i got from toyota canada:

Thank you for your recent correspondence.

Please be assured that we certainly do not like to see our customers experience the frustration and inconvenience that is associated with unexpected repairs. However, we would like to mention that extensive planning and research is required in order to ensure the highest quality of components are used on our vehicles. However, it is difficult to establish the life expectancy of a component or predict when a failure will occur. There are many variables that will contribute to their durability.

We have noted your comments and have forwarded them to the appropriate departments within Toyota Canada Inc. for information purposes.

Thank you again for taking the time to contact us.

Sincerely,

Alice ≈≈≈≈≈≈≈
Customer Interaction Centre
Toyota Canada Inc.

 

[lifesaver71]

Calipers

I have a 2005 T4R SR5 v6 with 170k miles, and I have replaced both front calipers twice.

@80k I did my first brake job turning the rotors, new pads, and remanufactured calipers

@120k I put new pads/new rotors only (Toyota OE rotors), calipers were OK. Also replaced wheel bearings at that time

@160k I replaced both calipers once again, new pads, rotors were still almost pristine, so no resurfacing.

Notice the trend. Seems the calipers are good for about 80k here in New England where the roads are salty all winter. Not too bad in my opinion.

The original Toyota rotors got me 120k first time around, figured I couldn't go wrong there.

I bought A1 Cardone remanufactured calipers online @ partstrain.com. There core charge is fairly steep ($90 or so), but even with the shipping to return the core, total cost still beat the local store, plus it comes right to the house in a few days time.

 

[LB4Runner05]

110k mile brake job

I am the original owner of my 05 4runner and I must say the brakes have served me pretty well. I do all my own work with the exception of tires.

My original front brakes were good till 68k with pads only, calipers and rotors
Good. At 110k I replaced the orig front calipers and rotors and did the pads since I was there.
My rear brakes were good till 98k and while in Iraq the wife had
To have the rotors changed. The problem is they used cheap parts and you can tell it's not the same. I will have to redo with good parts.
The calipers were easy to take off as
Long as you use a sawzall and knock the pins put. Overall the front calipers, rotors and pads and bleed took about 4'hours. :lookout

 

[utobiaus]

I talked to a couple mechanics that work on Toyotas. They said the frozen calipers have nothing to do with the calipers themselves. Apparently brake lines absorb moisture and water is heavier than brake fluid so the water settles at the bottom of the lines and we see frozen calipers as a result. They all recommend draining the brake fluid every two years and vac-ing the lines and they haven't had a problem when people do that.

Therefore when just changing the calipers without changing the brake fluid will result in frozen calipers forever.

 

[Veritas]

Anybody have pictures yet?

 

[MidwestT4R]

I forgot to mention that when I went to pick up the calipers the young guy behind the counter asked me what color caliper paint I wanted. It didn't click right away, but I realized that the calipers were spotless and he was suggesting that I paint both of them before installing. Like red or black or whatever.

I didn't do it but some of you who are into customizing your runners might give it some thought. Just get the calipers before you do your brake job, tape em up and paint away. Might be a nice cheap mod.

 

[songbird]

replacing all the brakes

well, during my adventure of my soft brake pedal thinking master cylinder or brake booster... I removed the front tires and started looking at the calibers, to my suprise.. A STUCK CALIBER PISTON on both calibers:mad2:... well tried to clean and get the pistons to work, no luck, I got fed up PO, went to auto store and bought new ones, replaced front calibers and installed cermic pads...went to the rear and found out I had a blown wheel cylinder.. looked like grease all over the place...so back to the auto store and got a new wheel cylinder and drum pads... two weeks later I thought to myself, hey master mech.:noidea: put new rotors and drums on... so I'm doing it this weekend... also ordered new stainless steel brake hoses for front and rear...my investment is under 400 bucks..my time is priceless... but then I will have a new brakes all around...if you want my to take pics I could...
Oh, just traded for this t4r it has 240,000 and runs strong..love toyota's..but I'm hoping all this will last... thanks for letting me unvent...is budwieser still in business....lol oh also going to paint calibers and drums..carefully...

 

[ronsta]

Having new calipers replaced as we speak, lower inside piston froze as well like everyone else. $400 for the whole job including replacing my front brake pads which I provided. Fair price ?

 

[preacher35]

Having new calipers replaced as we speak, lower inside piston froze as well like everyone else. $400 for the whole job including replacing my front brake pads which I provided. Fair price ?

Hmmmm... Are the rotors being replace or turned down? A remanufactured caliper is $80.00 and two, of course are $160.00 (and they probably do a mark up), so about $200.00 for labor. Yeah, that sounds about right. I personally, would have done the entire job myself, but I have a lot of tools that I have to justify to Mrs. Preacher.

 

[ronsta]

rotors were untouched, shop said they were fine so just calipers replaced, its been a tad over a month and already have rust on them...

 

[MikeInNH]

They said the frozen calipers have nothing to do with the calipers themselves.

Sorry..but that's total crap. I'd fine a new mechanic if he's telling you that. Brake fluid is hygroscopic - so yes they absorb water. But if this was the cause..then EVERY VEHICLE which had disk brakes would be having this problem. And they don't. This is a rare occurrence. And the new 4runners aren't having this problem. I hate those types of statements made by a so-called qualified mechanic. If he is a qualified mechanic...then he's lying through his teeth and shouldn't be trusted. There isn't a GOOD mechanic in the world who would believe that line. If the mechanic who told you this actually believes it..then he can't be trusted either, because he's an idiot.

 

[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.

 

[iAlex684]

How do you know you have a frozen caliper?