Frozen Calipers - How many others had this problem?

[JG1911]

How to prevent it? I assume its mostly caused by road salt in the north east.

Nope, it's happened to a friend here in Florida... He stalled on it so long that it caused damage and he had to shell out more money beyond a new caliper, rotor, pads.

I haven't had one yet, but I think I may be working on one. I'm getting a pulse now and my brakes/rotors are less than a year old, it's also intermittent, sometimes I get a pulse, sometimes I don't. I'm going to have the shop look at them when I have my 5100 and springs installed.

 

[Ducman]

Theory

I have read multiple theories on the reason for the failure of these trucks calipers. Some say to flush the brake fluid every season but I've also read a few of those same people have had frozen calipers anyway.

I personally think there a flaw of some kind with the design of the piston bore and that when the piston gets extended out past a certain point (say 75% of its travel or more) it is much more likely to freeze up.

I could be wrong but I think the best way to combat this failure is to change the brake pads a little prematurely (when they are down to half way or so) in order to keep the pistons from having to extend so far out of the calipers. Pads are cheaper than calipers.

*Has anyone had frozen calipers with more than 50% of the pad material left?

Using nice thick, quality rotors I believe also helps this issue to some degree too. I replaced my stock rotors although they looked 'ok' and were not badly scored or anything, the new Napa Ultra premiums I replaced them with were definitely thicker which means the stockers were worn down albeit pretty evenly.

I also think lubing the brake pad 'tabs' front and rear and replacing and lubing the slide pins up front is something every 4Runner owner should do annually.

 

[MICA4R]

ThanX for all the input on prevention...

Can we take it a step further and see if Yota will make a recall?

If we get enough people together I can get a petition together and have a JD friend of mine write an official letter... We can ask to get reimbursed for the issue if it has already occurred, and free replacement for those in the future

Given the number of people with the issue it seems like. Design flaw. That may be hazardous...

( way to kick Yota when it's down, I know )

 

[thirstyturtle]

Happened to me. Both rear calipers. Locked up and ruined my rotors and pads. Ordered new calipers, rotors, and pads for $260, will be installing today, hopefully with no hiccups along the way!

 

[noles2g]

seized in the south too..

Both front were seized on mine here in FL..at 80k with over 50% pads and newer rotors.. went Napa for rotors n calps.

 

[4Beast]

As I noted in another thread about this, both of my fronts were frozen and I ended up having my mechanic do it for $750ish including both rotors, both calipers and both sets of pads (plus one line). Kind of pisses me off that this is a well known problem but Toyota has not stepped up and don a recall or even provided some fix so that it won't happen again...

 

[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.

 

[lbrunner]

Another caliper

Just replaced the same front caliper that seized at 64K after replacing pads. This time I made it 30K. Had auto zone rotors and Cmax pads with a re-manufactured Toyota caliper installed at 64k at the dealer when at around 94K wife was complaining of pulsing.
So I got new rotors and pads again and I went 5 miles before the caliper would not release. It was the lower piston that would not retract...again.
Wow...30K and the same caliper fails. I think they make these calipers to do just that, fail, or piss poor design on the truck.
Look at the corrosion inside the piston. What junk. I went with a caliper from autozone this time. I least they have a 2 year warranty. I got one year with that junk Toyota caliper and made it 1 year 10 months.
Very disappointing. We have to plan on replacing calipers whenever we touch this brake system. What garbage. I guess its the price we pay for no other issues or problems to deal with.

 

[Res957cue]

mine happened monday

 

[futbolking]

Couple of questions. Is there a tell tale sign of this? Read about the pulling to one side. But, is this only when braking? Also read this is still a problem with new & rebuilt calipers. Is there an aftermarket option?

 

[BlackWorksInc]

Has anyone mapped out the locations of these failures? I see so many central and eastern stat owners complaining about siezing calipers, but I ask around at our dealer or the other repair shops here in Northen California and none of them really recall ever coming accross this issue...

 

[stanleybb50]

Has anyone mapped out the locations of these failures? I see so many central and eastern stat owners complaining about siezing calipers, but I ask around at our dealer or the other repair shops here in Northen California and none of them really recall ever coming accross this issue...

Must be 100% salt related then. Thx for the info.

- Sent via Tapatalk for Android

 

[Gatafly]

Anyone ever try the calipers from O'Reilly? They have a limited lifetime warranty. Not sure what the limited part is about, but I buy most of my stuff from there and when my starte failed they replaced it no questions asked. I have always been happy with their stuff and service. Sucks they freeze up so much, but this might make it so you don't have to keep buying new ones.

 

[BlackWorksInc]

Must be 100% salt related then. Thx for the info.

- Sent via Tapatalk for Android

I can't really say its from the salt, if I could map it out and see more pictures of failed calipers maybe I could give a better informed answer.

 

[realyfishy]

Must be 100% salt related then. Thx for the info.

- Sent via Tapatalk for Android

.:rant:
My 05 never left South Florida & I got 135,000 before the rt front seized. The NAPA replacements lasted 1,000 mi before one failed. Now with 146,000 one feels like it's starting to go. Here we go again!

 

[mahabali]

I just replaced both of my fronts last week. They were both frozen

I only have 72K miles

 

[Champ306]

one frozen on mine. and to bleed brakes was a major PITA. horrible. I just took mine apart and cleaned it all up. I wasnt paying a buck fifty at crap zone for something I could do.

rip off. and bad Toyota. bad.

 

[charlier180]

The left front caliper froze on my 4Runner last year after 6 years and 35K miles. I am starting to get the feeling that one of the other calipers may be having issues. Hopefully the weather is nice this weekend and I have time to pull the wheels and check all the calipers. If I have another frozen caliper you can bet your butt that I will get it fixed before my extended warranty runs out later this year.

 

[chucknorris]

I just picked up an 05 SE two weeks ago with 60k on the odo. I did notice some warping on the rear rotors, but didnt think too much of it since I am planning on swapping to slotted/drilled rotors anyways. But with all the complaints here, I am now worried the warping is due to frozen pistons and not heat related (im in AZ).

The fronts are fine and I got to test the ABS yesterday when some soccer mom decided to slam on her brakes mid lane change on the freeway off-ramp. ABS kicked in and I stopped pretty quick from about 30mph, no pulling to one side, nice straight line chirping to a stop.

Guess I'll be checking the caliper condition when I swap to drilled/slotted rotors and new pads.

 

[4runner norm]

4 Runner Norm

I had to replace the right front Caliper. One piston was stuck (rust) around the outside of the fluid seal. I broke it loose but I damaged the piston. Toyota sells pistons and seals. I did this on a Sunday so I bought a rebuilt Caliper from NAPA.I rebuilt the drivers side with new seals from Toyota.