Toyota Hiace (1989–2004) Brake Rotor Installation Tips
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Replace Pads & Inspect Calipers Thoroughly
Always replace the brake pads when installing new rotors. On older Hiace models, calipers may show signs of corrosion, seized pistons, or uneven wear—inspect carefully and rebuild or replace as needed. Also check for cracked or brittle brake hoses.
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Properly Suspend the Caliper
Use a caliper hanger to support the caliper from the suspension. These vans are often 20+ years old—never let the caliper hang from the original brake hose, which may be weakened over time.
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Clean the Hub Face Completely
After removing the old rotor, thoroughly clean the hub face with a wire brush or drill-mounted abrasive pad. Hiace hubs often have rust buildup that can cause rotor runout and vibration. Apply copper anti-seize to prevent future seizing and ease future service.
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Lubricate Proper Points Only
Apply brake grease to:
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Caliper slide pins
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Abutment clips
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Pad tab edges
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Back of the pads
Never apply grease to the friction surface of the pad or rotor. On Hiace vans with older calipers, confirm that the slide pins move freely before reassembly.
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Retract Pistons Carefully
Use a caliper piston compressor to retract pistons fully. Hiace calipers may resist due to age or buildup. Open the master cylinder reservoir to relieve pressure and monitor brake fluid level closely—older systems may overflow easily if topped off recently.
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Final Check & Bed-in Procedure
After reassembly, pump the brake pedal several times to seat the pads and verify a firm pedal feel. For best results, perform a proper bedding-in procedure to ensure even pad transfer and optimal braking performance.
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