The rotors are arguably the most important of all of the components of the 2002 Toyota 4Runners brake assembly. The rotors provide the platform on which the brake pads rely to slow and eventually stop the vehicle. Damaged rotors will compromise the effectiveness of the brakes, leading to uncontrolled braking and possibly brake failure. Inspect the rotors regularly for scoring and other damage to catch any repair or replacement needs as soon as possible.
1 Park the 4Runner on a flat surface and turn the engine off. Open the hood and remove the master cylinder cap located on the right side of the engine, near the back of the engine compartment. Remove 1/3 of the brake fluid from the reservoir with a turkey baster. Place a shop rag over the containers opening.
2 Place tire blocks in front of the front tires. Loosen the lug nuts on the rear wheels with the 17-mm socket and breaker bar. Place the jack under the frame in the back of the vehicle and lift the rear wheels off the ground. Rest the rear axles onto jack stands and remove the jack. Remove the lug nuts and take the back wheels/tires off.
3 Remove the caliper slide bolts on the right rear caliper with the 14-mm wrench. Lift the caliper from the caliper bracket and suspend it above the brake assembly with a wire coat hanger or bungee cord. Remove the brake pads from the caliper bracket by hand. Each of the two pads will slide from the caliper bracket slots on either side of the right rear brake rotor.
4 Remove the caliper bracket bolts with the 16-mm wrench. Lift the bracket from the rotor and set it aside.
5 Tap the center section of the rotor with a dead-blow hammer to loosen the grip of rust on the back side of the rotor. Grab the rotor on both sides and pull it straight from the wheel hub.
6 Spray brake parts cleaner on the wheel hub and clean the area with a wire brush to remove rust and other debris. Clean the new brake rotors thoroughly with brake cleaner and a cloth towel.
7 Place the new rotor on the wheel bolts with the raised center section facing out. Replace the caliper bracket on the rotor and screw in the caliper bolts. Slide the new brake pads into the bracket slots on either side of the rotor.
8 Place the C-clamp over the caliper piston and the back side of the rear caliper. Squeeze the piston into the side of the caliper. Remove the clamp after the piston has been forced completely inside the caliper wall. Place the caliper over the bracket and the new brake pads. Screw in the caliper slide bolts and tighten them with the 14-mm wrench.
9 Move to the opposite side of the 4Runner and replace the left rotor and brake pads (follow Steps 3 through 8). Place the wheels back on the Toyotas rear wheel bolts and screw on the lug nuts by hand. Lift the rear-end of the 4Runner with the jack and remove the jack stands. Lower the rear tires to the ground and tighten the lugs with the socket and breaker bar. Return to the drivers seat.
10 Start the Toyotas engine and press the brake pedal repeatedly until the pedal response returns to normal. Move to the engine compartment with a funnel and brake fluid. Remove the shop rag and place the funnel inside the reservoir. Fill the master cylinder with brake fluid. Remove the funnel and replace the master cylinder cap. Close the Toyotas hood.
