Nightmare Brake Job

[KrazedJD]

Dropped 4R off for new timing belt n plugs for 90k service which I am 10k behind on. They call me and confirm I have seized calipers on both driver and passenger side. Inquiring how much they tell me a number that is way beyond what I want to pay ($800). So I decide to buy new rotors ceramic pads and re-manufactured calipers ($500).

Went to auto zone and truthfully I was worried about the size issues, more so with the rotors. Got everything and it looked great till I mounted the calipers. They lined up great during the bolting but after taking a look after installing it pads hung 3/8" over rotor. Rotor was right size caliper looked right but the bolt pattern was a lil off extending rotor outwards more. Took em back and they realized the mistake, no biggie except the right caliper actually cost more.

Get new calipers which are the right size. Install everything last night and during bleeding I notice a puddle under passenger side. At first thought I did not torque the brake line to caliper enough or left the bleeder valve open. None of the above, the leak was coming from the center of the caliper. The two halves were leaking a steady drip. I tried tightening the bolts holding them together no go no matter what I did could not stop the leak.

Anyone else ever experience this, took it back one more time hopefully next set is the final time I have to deal with this?

In hindsight the money difference its seems would have been worth the extra $300 to have Toyota deal with this?

 

[Jerrydog]

Sorry to hear about your trouble, sometimes you get shoddy parts its unavoidable. Im more concerned that BOTH calipers were bad at 90k. I just sold my 97 Pathfinder with the original calipers 304k miles. I'd be looking for an explanation from Toyota and maybe get them to pay half that fix.

 

[DaveS]

Sorry to hear about your trouble, sometimes you get shoddy parts its unavoidable. Im more concerned that BOTH calipers were bad at 90k. I just sold my 97 Pathfinder with the original calipers 304k miles. I'd be looking for an explanation from Toyota and maybe get them to pay half that fix.

He did better than a lot of us - and yes many of us would like an explanation but I doubt one will be forthcoming. I had both fronts go just inside warranty at 36,000 miles and had a second one of the fronts replaced recently at around 85,000 miles (now it's a matter of time for the second I suspect). The more salt you have on the roads round you, the more likely you are to have this issue it seems. You would think Toyota would either brass line the cylinders or put some kind of splash guard in there to stop salt getting in - it always seems to be the same one of the 4 pistons that seizes so it's not impossible to design out.

 

[Jerrydog]

Is it the slide pins seizing or the actual pistons?

 

[KrazedJD]

Is it the slide pins seizing or the actual pistons?

It is the pistons that seize. In my case the pins came out very easily. I will try to get a pic of the old ones up tonight.

Once my old calipers were out and I knew it was ok to beat on them I tried to compress them with a huge clamp and nothing would budge em. The thought of a rebuild kit crossed my mind, no way save yourself the trouble and just go with new.

I think I read somewhere someone preemptively bought new calipers for the brake job and if not this time they would need them for the next time.

You would think Toyota would either brass line the cylinders or...

Funny you mention that, the calipers I got with the cast letters WH13 were brass coated and cheaper then the proper ones. I wonder if the WH13 were the ones found on tundra or if I could have found a rotor that fit them then never have to worry about seized anything ever?

 

[eliask08]

KrazedJD, sorry to hear that. I am assuming they did not pressure test the halves together during the recertification. I purchased a set of EBC rotors and pads for the front and rear, and replaced the rear first seeing that it was an easier task. When I got to the front, the lower-inner piston was seized on both calipers - probably due to poor design. I managed to put them back together with the old rotors, only to lose a bit of stopping power. I am waiting for the weather to warm before reattempting with remanufactured calipers.

As for the casting number, I believe the difference is the size. The Sport Ed comes with slightly larger rotors, and thus require a slightly larger rotor.

 

[4runr30]

That sucks! I feel part of your pain though I had to have new calipers replaced this past week along w pads. What is the deal with calipers freezing up?? I had a little more luck though made it out the door for $412 w new calipers and pads and had the rotors machined. Hope everything works out.:cheers:

 

[audiness]

similar thing happened to me. I bought 2 re manufactured front calipers from napa, get them all bolted on, and one of them was leaking from the seal! Had to drive all over creation to find another one, seems that the ones I needed were an uncommon size. then just a few weeks later, one of my rear calipers seized. So I have 3 out of 4 "new" calipers, and a skinnier wallet

 

[MJ Philbin]

I have a 03 LTD v6 and have replace both my front ones, but the backs are still good at 160K miles. I will say that any time I've gone for anything but pads for this truck, it's been a nightmare getting the right parts. It seems like Toyota released 2 different size rotors and/or calipers, even for the 17" wheels. The first time I did the brakes, I knew I wanted to get the rotors cut, but couldn't line up an alternative vehicle to use in the mean time so I bought a second set of rotors to complete the job. They were too big to fit inside the space allowed. Had to drive all the way back to a supplier that was 15 miles away. Even Tire Rack shows 2 potentially different sizes for a 4wd Limited, which all had 17" wheels from the factory. Go figure!

Someone else commented above on how it stinks to have had to replace the calipers at such an early age. The funny thing for me is that I'm still on my original headlights and tail lights, but have already replaced all 4 oxygen sensors, the tailgate locking assembly, the tailgate window regulator & motor, and a handful of other oddball items that I wouldn't have expected.

 

[DaveS]

4 O2 sensors is scary. The Ltd in 03 had the regular sized brakes I believe something like 12.6" - only the sport had the larger 13.3" discs even though both came with 17" rims. Confusing for parts suppliers as well as consumers because in later years they started offering the larger discs on the limited as well.

 

[KrazedJD]

Not sure about you guys and this is def off topic, but I am tired of having to replace dash illumination bulbs, seems like a new one every other month is going out. I have had cars that have lasted 15 years 250k miles and never had to replace a factory illumination bulb!