2012 Toyota Prius TwoFACTORY OEM SERVICE PROCEDURE

Front Brake: Reassembly: Reassembly

WARNING: This page is about a different variant/trim than selected.
  1. TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG 

    HINT: 

    Fully tighten the front disc brake bleeder plug after bleeding any air left in the system.

  2. INSTALL FRONT DISC BRAKE BLEEDER PLUG CAP 
  3. INSTALL PISTON SEAL 
    1. Apply a light layer of lithium soap base glycol grease to the entire circumference of a new piston seal.
      Fig 1: Identifying Piston Seal
      GTY263991Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      Lithium Soap Base Glycol Grease
    2. Install the piston seal to the disc brake cylinder assembly.
      NOTE:

      Securely install the piston seal into the groove of the disc brake cylinder.

  4. INSTALL FRONT DISC BRAKE PISTON 
    1. Apply a light layer of lithium soap base glycol grease to the entire circumference of a new cylinder boot.
      Fig 2: Install Front Disc Brake Piston
      GTY324138Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Cylinder Boot
      *2 Front Disc Brake Piston
      Lithium Soap Base Glycol Grease
    2. Install the cylinder boot to the front disc brake piston.
    3. Apply a light layer of lithium soap base glycol grease to the contact surfaces of the front disc brake piston, and install it to the disc brake cylinder assembly.
      NOTE:

      Do not install the piston forcibly in the disc brake cylinder assembly.

  5. INSTALL CYLINDER BOOT 
    1. Install the cylinder boot to the disc brake cylinder assembly.
      Fig 3: Identifying Cylinder Boot & Set Ring
      GTY213895Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Set Ring
      *2 Cylinder Boot
      NOTE:

      Securely install the cylinder boot to the groove of the disc brake cylinder assembly and front disc brake piston.

    2. Using a screwdriver with its tip wrapped with vinyl tape, install a new set ring.
      Fig 4: Removing Cylinder Boot
      GTY217353Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Vinyl Tape
      NOTE:
      • Securely install the set ring to the outer groove of the cylinder boot.
      • Do not damage the cylinder boot.
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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.

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