My 2005 Scion xB: Update #3

 Replacement of all front brake hardware.

I recently heard squealing coming from my front passenger side wheel when applying the brakes. I thought I had checked my pad depth in the last year or two, but maybe it had been a while. I decided to check it again, and my passenger side was down to the metal warning tab on the inside pad (meaning the pads needed to be changed out ASAP). There was a little more material left on drivers side.

All front and rear hardware 

Old driver's side hardware, about to remove

New stuff installed on passenger side

I ordered a kit from Ebay that had front pads and rotors as well as all rear drum hardware.

brake caliper diagram

This car is basically my daily, and winter car. The calipers had been though 16 Wisconsin winters, and were covered in a layer of rust. They still worked fine, as far as I could tell. However, the look of the pistons made me decide to go ahead, and replace calipers and hoses, since I was in there.

Piston was rusty, and I thought now seemed to be a good point to replace.

New caliper next too the old.

I bought Raysbestos brand, new hoses and remanufactured calipers. 

I applied synthetic brake grease to both sides of the new pad mounting clips, and to both the piston, and the opposing side of the caliper, where it would contact the shim of the outside pad. Basically, any metal on metal, or pad contact, got grease to eliminate rattles. Slide pins were newly greased from the manufacturer, so I didn't do that.

New pad and rotor sandwich, in the mounting bracket, before caliper is attached

The backing plate on the passenger side was completely gone. (it protects the inside surface of rotor from dirt and grime, extending pad life) Probably removed by a mechanic, the last time pads and rotors were done, at the dealership, 5-ish years ago. This explained why the passenger side pads, were worn down more. Similarly, the drivers side backing plate was hanging on by a thread, so I ripped that one off too. (Not replacing these, as that requires the hub to be pulled.)

Remains of drivers side backing plate

I got all hardware attached, and unlike a standard brake job, this one required brake fluid to be bled. After that, I took it for a first drive and "bedded" the brake pads by doing a series of smooth brake applications from 45 - 5 mph, and then from 60 - 10 mph. This is to transfer some pad material evenly to the rotors, before use.

Torque specs:

Mounting bracket to knuckle: 65 ft lbs.
Caliper to mounting bracket: 25 ft lbs.
Banjo bolt connecting hose to caliper (2 copper washers) 22 ft lbs.
hose to brake hardline fitting: just tightened by feel (11 ft lbs.)

Project cost:

Brake hardware kit - rear and front (pads, rotors, drums, shoes) $141
Front calipers (Raysbestos - remanufactured) $251
Raysbestos front hoses $64

(core charge refund for 2 old calipers, from seller +$75)

Total : $381

Coming up next time: Rear drum brakes changed out