The Infamous FROZED UP brake Caliper

natevans65

New member
Had my OEM front brake calipers replaced by Toyota at 142K miles, they were severely corroded, once replaced....all was good. Within the last 5K miles....I've noticed that every time I brake, it pulls hard left. Put the Runner on the lift today, pulled the right side tire/rim and tested the pistons....and to my SU-Prise.....all frozed up---AGAIN! I now:ybrick: have 165K on them and will AGAIN replace them with a non-OEM replacement. Any suggestions???
 
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so you got 142K on the first set and 165K on the second set ?
are you in a winter salt road area ?

Just curious, how much warranty did Toyota give on the first replacement ?
 
Good question: I did not think to go back to them to see what the warranty is on them. I live in the Virginia area...cold, wet, some snow. With the original calipers...they lasted 142K miles in the same climate...never out of the Mid-Atlantic area so to speak so they were subjected to the same climate all the time. I only got a short 23K miles on the replacements (both fronts). I will contact Toyota in Maryland (Fitzgeralds) were the work was done. Thanks!
 
I've only had frozen calipers, never had FROZED UP ones...

Ahhh, I kid, I kid. Anyways I replaced mine with NAPA re-man units and they have been holding up well. They come painted black and are about 115/ea. I believe they have a lifetime warranty also.

That being said, I think there are cheaper Duralast calipers available at Autozone that also come with a lifetime warranty.

Edit: Flushing your brake fluid is probably also a good idea. Old brake fluid typically has extra water in it, which can lead to premature corrosion of the piston (hence the sticking/freezing).
 
All good ideas. I went up online and went to the Toyota site where you can plug in your VIN, create an account and you can see all your service work. I also spoke to the dealership and found out that I am 3 months outside the "warranty" that they provide when you get work done with them. Sent an email to the service manager and will follow up live with him to see what help they can lend. I like the NAPA idea...lifetime warranty! Thanks!
 
UPDATE: The dealership said bring it back in....they will look at it and then go to bat for me with Toyota if it is determined that it is in fact "all frozed up" So...stay tuned!
 
Natevans65 I also live in va I work at a dealership and what I've noticed is when you change calipers you should change the brake fluid as it is hydroscopic and causes caliper pistons to rust internally
 
So, I had a similar problem with mine. I had to replace my cv shaft. I'm getting the second one done on Monday, because I'm getting the same problem on the right side now. When you break the car will pull in one direction.
Does it feel like the tire is unbalanced, or like abs is kicking in when you break at all?
 
Is this typically only on the front calipers or all 4 wheels?

I have been hearing of this more and more lately. At 140K miles on a 2003 4Runner that came from Colorado, I feel like I am on borrowed time. I did replace the pads and rotors for the first time in the vehicles life within the last year and the calipers compressed just fine.
 
Update #2: Dealership said...YEP...they are sticking and SORRY...Toyota will not anty up to help with calipers freezing up with only 24K miles on them. I put in a call to the Toyota Customer Service Center to lodge a case and supposedly I will hear back on the ruling within 3 business days. I am supposed to hear how the mid-Atlantic Toyota Service Center Rep rules on this. I asked the service center rep do I get a chance to speak with them and was told....NO...the dealership will call you back once they have their discussion first and then you will get the ruling. When I picked up the truck this morning and mentioned the infamous brake caliper issues with 4Runners to the General Service Manager at Fitzgerald's....he looked dumb founded and had never heard of 4Runners having this issue. Riiiiiiiiiight......Any who, I can understand that perhaps around 70-80-90K miles they might start to have issues...but at 24K miles that was just serviced a year ago??? Come on.....

Yes...when I did the brake replacement, I drained and filled the brake system with new fluid....so during this past 24K miles I have had fresh fluid in the system. It's a synthetic Amsoil brake fluid that is found at this link..

https://www.amsoil.com/storefront/bf3.aspx

More to come!
 
This is what I found after removing the right front Caliper from My 2004 Toyota 4Runner . One of the pistons was frozen (rust) outside of the fluid seal. It looks like the rubber boot did not keep the water out. I replaced it with a NAPA re-man Caliper. The left front I rebuilt with a Seal Kit from Toyota. They also sell the pistons.
 

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Piston

Do you happen to remember the price on these items? How hard was it to remove the piston? Did you need a tool, or did they just come out?

I have this symptom where when I apply my brakes, I hear a clank sound from the right front, then the left front. It's almost as if the pistons are engaging slowly... maybe they need more pressure now to move due to rust, etc...

PS: I live in the Chicago area, and I only have 57K on my 2008 limited.
 
anyone else have this issue lately?

Just replaced both my front calipers yesterday after work (they were NAPA remans so the new parts were 'free' under warranty). The best solution short of a big brake kit from Stoptech is to just replace the calipers with re-mans that have a lifetime warranty. If they fail again, just replace and you're out the couple hours it takes to swap them and flush fluid.

Good time to flush the brake fluid too as someone further up the thread suggested.
 
Yup, just did my front left caliper. It was also a NAPA reman, replaced under warranty for the third year in a row. It seems I have to replace this caliper yearly.
 
Just replaced another rear caliper a few weeks ago. That makes 5 total calipers in over 160k (once per, with the passenger rear repeat).

I did the rebuild once, got the T-shirt, don't care to do it again.

This last one was frozed up (sorry, couldn't resist!) and I removed it, soaked it with PB Blaster inside, rinsed several times with brake fluid, reinstalled and it was shortly the same drag, so replaced it.

Advance Auto has the rears, about $70 with about $70 core (return the old one for credit) WITH the bracket. Drop dead simple choice.

IIRC, I ordered the fronts from autopartswarehouse com for about $90/ea a couple of years back. The slide pins were MUCH, MUCH better than the originals. They have never rusted to a larger diameter like the originals.

Use never sieze in the right places, changes are very easy.

I use an empty coffee can an let the brake fluid drip into it while changing calipers. Make sure your reservoir is filled, cap off but sitting on top to reduce chances of contamination by moisture or debris.

I open the bleeders and then tighten, then loosen again BEFORE installing. Sometimes the threads are a bit tight and this helps break things in and seat in correctly where you can actually get at it ;)

Push the caliper piston all the way into the caliper to avoid getting air trapped in the piston.

I then fill the caliper with brake fluid, let it sit a few mins, dump it out, refill, then install.

Once you've installed the brake line, I leave the bleeder cracked open and let some fluid run out before tightening the bleeder. It REALLY speeds up the brake bleeding process.

Note that it is important to clean up all the brake fluid as it RUSTS EVERYTHING!

Don't forget to top off the reservoir with brake fluid (Fill line) and put the cap back on.

Tips:

1. Be sure you don't forget the crush washers on the banjo bolt (bolt of the brake line with the hole through the center).

2. Make sure the flat part of the brake line bracket lines up with the one on the caliper and is facing away from the rotor

3. Be careful not to pinch, kink, or otherwise damage the brake line. If changing just the brakes (not the caliper), I use a piece of wire to tie the caliper to the coil to keep its weight off the brake line.

IMHO, it seems that the rear pistons have a high fail rate if you let the brake pad get down too far. It appears the piston comes out and then wants to kink (maybe?) and stick.

For $70, it's a no-brainer to replace as necessary, IMHO.

I tow often, we have rough, windy, and hilly roads, we offroad as we feel like it, we get lots of snow/salt/junk on the roads. We often have to drive through a foot of snow for days or weeks at a time. I think I get my $$ worth.

Hope this helps!
 
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bought my 4th gen with 129k on the clock. Replaced drivers side front caliper. Now 3 years later it is time to replace the passenger side caliper.

This sucks. Rather be working on my dirtbike.
 

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