Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSTOYOTA2002HIGHLANDER 4WD L4-2.4L (2AZ-FE)REPAIR AND DIAGNOSISTRANSMISSION AND DRIVETRAINAUTOMATIC TRANSMISSION/TRANSAXLESERVICE AND REPAIRDISASSEMBLY/INSPECTION/REASSEMBLY OF COMPONENTSSECOND BRAKE PISTON
2002 Toyota Highlander 4WD L4-2.4L (2AZ-FE)
Second Brake Piston
2002 Toyota Highlander 4WD L4-2.4L (2AZ-FE)SECTION Second Brake Piston
OVERHAUL
1. REMOVE 2ND BRAKE PISTON RETURN SPRING SUB-ASSY [35608/98-6]
a. Place SST on the return spring and compress.
SST 09387-00060
b. Using a screwdriver, remove the snap ring.
c. Remove the piston return spring.
2. INSPECT 2ND BRAKE PISTON RETURN SPRING SUB-ASSY
[35608/98-6]
a. Using a vernier calipers, measure the free length of the spring together with the spring seat.
Standard free length: 16.61 mm (0.6539 inch)
3. REMOVE 2ND BRAKE PISTON [35624/98-6]
a. Hold the 2nd brake piston and apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the 2nd brake cylinder to remove the 2nd brake piston.
4. REMOVE 2ND BRAKE PISTON O-RING [35624A/98-6]
a. Remove the 2 O-rings from the 2nd brake piston.
5. INSTALL 2ND BRAKE PISTON O-RING [35624A/98-6]
a. Coat 2 new O-ring with ATF, install them in the 2nd brake piston.
6. INSTALL 2ND BRAKE PISTON [35624/98-6]
a. Press in the 2nd brake piston into the 2nd brake cylinder with your hands.
7. INSTALL 2ND BRAKE PISTON RETURN SPRING SUB-ASSY [35608/98-6]
a. Install the piston return spring.
b. Place SST on the piston return spring, and compress the piston return spring with a press.
SST 09387-00060
c. Using a screwdriver, install the snap ring.
NOTICE: Be sure the end gap of the snap ring is not aligned with the piston return spring claw.
1. REMOVE 2ND BRAKE PISTON RETURN SPRING SUB-ASSY [35608/98-6]
a. Place SST on the return spring and compress.
SST 09387-00060
b. Using a screwdriver, remove the snap ring.
c. Remove the piston return spring.
2. INSPECT 2ND BRAKE PISTON RETURN SPRING SUB-ASSY
[35608/98-6]
a. Using a vernier calipers, measure the free length of the spring together with the spring seat.
Standard free length: 16.61 mm (0.6539 inch)
3. REMOVE 2ND BRAKE PISTON [35624/98-6]
a. Hold the 2nd brake piston and apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the 2nd brake cylinder to remove the 2nd brake piston.
4. REMOVE 2ND BRAKE PISTON O-RING [35624A/98-6]
a. Remove the 2 O-rings from the 2nd brake piston.
5. INSTALL 2ND BRAKE PISTON O-RING [35624A/98-6]
a. Coat 2 new O-ring with ATF, install them in the 2nd brake piston.
6. INSTALL 2ND BRAKE PISTON [35624/98-6]
a. Press in the 2nd brake piston into the 2nd brake cylinder with your hands.
7. INSTALL 2ND BRAKE PISTON RETURN SPRING SUB-ASSY [35608/98-6]
a. Install the piston return spring.
b. Place SST on the piston return spring, and compress the piston return spring with a press.
SST 09387-00060
c. Using a screwdriver, install the snap ring.
NOTICE: Be sure the end gap of the snap ring is not aligned with the piston return spring claw.
RENDER: 1.0x
NO RELATED
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.