T-SB-0248-12

T-SB-0248-12
December 21, 2012
Uneven Wear on Rear Brake Pads
Service
Category
Brake
Section
Brake (rear)
Market
USA
Applicability
YEAR(S)
MODEL(S)
2012
Prius PHV
2010 – 2012
Prius
ADDITIONAL INFORMATION
Introduction
Some 2010 – 2012 model year Prius and 2012 model year Prius PHV vehicles may exhibit uneven
brake pad wear on the rear brake pads. The vehicle may also exhibit a grinding or scraping noise due
to the uneven brake pad wear. An updated rear pad kit has been developed to address this condition.
Production Change Information
This bulletin applies to vehicles produced BEFORE the Production Change Effective VINs shown
below.
MODEL
Prius
Prius PHV
PLANT
PRODUCTION CHANGE EFFECTIVE VIN
Tsutsumi
JTDKN3DU#C0336183
JTDKN3DU#C1577949
Toyota Auto Body
JTDKN3DU#C5496212
Tsutsumi
JTDKN3DP#C3022883
Parts Information
PREVIOUS PART NUMBER
CURRENT PART NUMBER
PART NAME
QTY
04466-47020
04466-47030
04466-47040
04466-47060
04466-47061
04466-47080
Rear Brake Pad Kit
1
08887-80409
Same
Disc Brake Shim Grease
1
© 2013 Toyota Motor Sales, USA
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December 21, 2012
T-SB-0248-12
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Uneven Wear on Rear Brake Pads
Warranty Information
OP CODE
DESCRIPTION
TIME
OFP
T1
T2
473311
R & R Rear Brake Pads
0.8
BR1207
Turn Rear Brake Rotors and Replace Rear
Brake Pads (Both Sides)*
2.0
04466-47020
04466-47030
04466-47040
04466-47060
04466-47061
91
17
* Do NOT claim both Machining and Rotor replacement. Only ONE or the other operation is allowed, if required.
APPLICABLE WARRANTY
• This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months
or 36,000 miles, whichever occurs first, from the vehicle’s in-service date.
• Warranty application is limited to occurrence of the specified condition described in this
bulletin.
Required Tools & Equipment
PART NUMBER
QTY
Variable Pin Wrench Set**
09960-10010
1
Companion Flange Holding Tool**
09330-00021
1
SPECIAL SERVICE TOOLS (SST)
** Essential SST.
NOTE
Additional SSTs may be ordered by calling 1-800-933-8335.
© 2013 Toyota Motor Sales, USA
December 21, 2012
T-SB-0248-12
Uneven Wear on Rear Brake Pads
Repair Procedure
Figure 1.
.
2. Inspect the pad support clips and clean off any
corrosion that might be on the brake cylinder
mounting plate.
Figure 2.
.
3. Remove the rear disc brake cylinder mounting.
Figure 3.
.
1. Remove the rear brake pads.
Refer to the Technical Information System (TIS),
applicable model and model year Repair Manual:
• 2010 / 2011 / 2012 Prius:
Brake – Brake (Rear) – “Brake (Rear): Rear
Brake: Removal”
• 2012 Prius PHV:
Brake – Brake (Rear) – “Brake (Rear): Rear
Brake: Removal”
© 2013 Toyota Motor Sales, USA
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December 21, 2012
T-SB-0248-12
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Uneven Wear on Rear Brake Pads
Repair Procedure (Continued)
4. Inspect the rear disc thickness.
Refer to TIS, applicable model and model year Repair Manual:
• 2010 / 2011 / 2012 Prius:
Brake – Brake (Rear) – “Brake (Rear): Rear Brake: Inspection”
• 2012 Prius PHV:
Brake – Brake (Rear) – “Brake (Rear): Rear Brake: Inspection”
A. Place a match mark on the rotor and the rear
axle hub to indicate their original positions.
Figure 4.
1
1
B. Using a micrometer, measure the disc
thickness.
Matchmark
Figure 5.
Standard Thickness: 9.0 mm (0.354 in.)
Minimum Thickness: 7.5 mm (0.295 in.)
1
1
Micrometer
C. If the disc thickness is less than specified, replace the rear disc.
© 2013 Toyota Motor Sales, USA
December 21, 2012
T-SB-0248-12
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Uneven Wear on Rear Brake Pads
Repair Procedure (Continued)
5. Inspect disc run-out.
Refer to TIS, applicable model and model year Repair Manual:
• 2010 / 2011 / 2012 Prius:
Brake – Brake (Rear) – “Brake (Rear): Rear Brake: Inspection”
• 2012 Prius PHV:
Brake – Brake (Rear) – “Brake (Rear): Rear Brake: Inspection”
A. Inspect the rear axle hub bearing and axle hub run-out.
B. While holding the disc to the hub with the SST,
tighten the hub nuts to the disc using the 5 star
pattern sequence.
Figure 6.
SST: 09330-00021
Torque: 103 N*m (1050 kgf*cm, 76 ft*lbf)
1
1
C. Using a dial indicator with a magnetic base,
measure the disc run-out 10 mm (0.394 in.)
away from the outer edge of the rear disc.
SST
Figure 7.
Maximum Disc Run-out: 0.15 mm (0.00591 in.)
NOTICE
• Keep the magnet of the dial indicator
away from the axle hub and speed
sensor.
1
• If the run-out exceeds the maximum
value, change the installation position
of the disc to minimize the run-out.
If the run-out exceeds the maximum
even when the installation position is
changed, grind the disc with on the
car brake lathe. If the disc thickness is
less than the minimum, replace the rear
disc.
1
© 2013 Toyota Motor Sales, USA
Dial Indicator
December 21, 2012
T-SB-0248-12
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Uneven Wear on Rear Brake Pads
Repair Procedure (Continued)
6. Install NEW rear brake anti-squeal shims with brake pads into the rear caliper assembly brackets.
Refer to TIS, applicable model and model year Repair Manual:
• 2010 / 2011 / 2012 Prius:
Brake – Brake (Rear) – “Brake (Rear): Rear Brake: Installation”
• 2012 Prius PHV:
Brake – Brake (Rear) – “Brake (Rear): Rear Brake: Installation”
A. Apply Disc Brake Shim Grease
(P/N 08887-80409) to the back plate of
the rear disc brake pads.
Figure 8.
1
00
00
00
00
00
2
00
00
00
3
1
Inner Pad
2
Outer Pad
3
Disc Brake Shim Grease
© 2013 Toyota Motor Sales, USA
December 21, 2012
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Uneven Wear on Rear Brake Pads
Repair Procedure (Continued)
B. Install the No. 1 disc brake anti-squeal shim
and No. 2 disc brake anti-squeal shim to each
rear disc brake pad.
Figure 9.
NOTE
3
• When replacing worn pads, the
anti-squeal shims must be replaced
together with the pads.
2
1
• Apply Disc Brake Shim Grease (graphite
based) to the inside surface of the No. 2
anti-squeal shim.
1
2
3
• Disc Brake Shim Grease may seep
out slightly from the areas where the
anti-squeal shims are installed.
• Make sure that Disc Brake Shim Grease
is not applied onto the lining surface.
• There should be no oil or grease on the
friction surfaces of the disc brake pads
or the rear disc.
1
Rear No. 1 Disc Brake Anti-squeal Shim
2
Rear No. 2 Disc Brake Anti-squeal Shim
3
Disc Brake Shim Grease
C. Install rear brake pads into caliper brackets.
7. Install the rear disc brake cylinder assembly and adjust the parking brake.
Refer to TIS, applicable model and model year Repair Manual:
• 2010 / 2011 / 2012 Prius:
Brake – Brake (Rear) – “Brake (Rear): Rear Brake: Installation”
• 2012 Prius PHV:
Brake – Brake (Rear) – “Brake (Rear): Rear Brake: Installation”
© 2013 Toyota Motor Sales, USA
December 21, 2012
T-SB-0248-12
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Uneven Wear on Rear Brake Pads
Repair Procedure (Continued)
A. To compensate for pad wear, use the Variable
Pin Wrench Set to turn the piston to the
position where the protrusion on the pad lines
up properly with the piston groove.
Figure 10.
90°
Retract: Clockwise
Extend: Counterclockwise
NOTE
Place the disc between the 2 brake pads
and determine the piston return value.
1
1
90◦
2
SST
B. Place the disc between the 2 brake pads and determine the piston return value.
C. Hold the rear disc brake cylinder pad guide
pin and install the rear disc brake cylinder
assembly to the rear disc brake cylinder
mounting with the 2 bolts.
Figure 11.
2
NOTE
• Install the rear disc brake cylinder
assembly while holding both of the
rear disc brake pads because the
anti-squeal springs may fall off the rear
disc brake pads.
1
• Be sure that the anti-squeal springs are
installed to the rear disc brake pads.
1
Hold
2
Turn
8. Test drive the vehicle and confirm the rubbing or grinding noise is no longer present.
© 2013 Toyota Motor Sales, USA