🔧 Highlander - Rear Brake Pads & Rotor Replacement

You’ll remove the rear calipers, replace the pads and rotors on both sides, then reassemble and bed-in the brakes. On your Highlander, rear brake service may require putting the electronic parking brake (EPB) into “maintenance mode” so the caliper pistons can retract safely.

Difficulty Level: Intermediate | Estimated Time: 2.0-3.5 hours

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⚠️ Safety & Precautions

• ⚠️ Work on level ground and support the vehicle with jack stands before removing wheels.
• ⚠️ If your Highlander has an electronic parking brake, do not force the rear caliper piston in without EPB maintenance mode.
• ⚠️ Do not let the caliper hang by the brake hose; support it with a hanger.
• ⚠️ Avoid breathing brake dust; use brake cleaner, not compressed air.
• ⚠️ If you open the brake hydraulic system, you must bleed the brakes before driving.

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🔧 Required Tools

You'll need the following tools for this repair:

• Floor jack (rated 3-ton minimum)
• Jack stands (rated 3-ton minimum)
• Wheel chocks
• 21mm socket
• Breaker bar (1/2")
• Torque wrench (1/2" drive)
• 14mm socket
• 17mm socket
• Ratchet (1/2" drive)
• Ratchet (3/8" drive)
• Flathead screwdriver
• C-clamp (6")
• Wire brush
• Bungee cord or caliper hanger hook
• Micrometer or vernier caliper (specialty)
• Brake cleaner
• Nitrile gloves
• Safety glasses

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Rear brake pad set - Qty: 1
• Rear brake rotors - Qty: 2
• Rear brake pad hardware kit (clips/shims) - Qty: 1
• Brake lubricant (silicone brake grease) - Qty: 1
• Brake cleaner - Qty: 1
• Threadlocker (medium strength) - Qty: 1

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📋 Before You Begin

• 🧰 Confirm whether your Highlander has an electronic parking brake switch (a P-in-a-circle button) on the console.
• 🧰 If it has EPB, plan on using a scan tool that supports Toyota EPB “maintenance mode” (this retracts the parking brake motor so you can compress the piston).
• 🧰 Park on level ground, chock the front wheels, and leave the parking brake OFF before lifting the rear.
• 🧰 Loosen rear lug nuts slightly using a 21mm socket and breaker bar before the wheels are off the ground.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Lift and secure the rear

• Chock the front wheels using wheel chocks.
• Lift the rear using a floor jack (rated 3-ton minimum) and support with jack stands (rated 3-ton minimum).
• Remove both rear wheels using a 21mm socket and ratchet (1/2" drive).
• Reinstall lug nuts finger-tight on one stud if you want the rotor to stay aligned during removal.

Step 2: Put the EPB in maintenance mode (if equipped)

• If equipped, connect your scan tool and command the rear EPB into service/maintenance mode. This prevents EPB motor damage.
• If your Highlander does NOT have EPB, skip this step.

Step 3: Remove the rear caliper

• Turn the steering slightly or reposition for access if needed.
• Remove the rear caliper slide pin bolts using a 14mm socket and ratchet (3/8" drive).
• Lift the caliper off the bracket and support it using a bungee cord or caliper hanger hook.
• Torque to 34 Nm (25 ft-lbs) when reinstalling the rear slide pin bolts.

Step 4: Remove pads and bracket

• Remove the old pads and any shims/clips using a flathead screwdriver if needed.
• Remove the caliper bracket bolts using a 17mm socket and breaker bar (1/2").
• Remove the bracket and set it aside.
• Torque to 90 Nm (66 ft-lbs) when reinstalling the rear bracket bolts.

Step 5: Remove the rotor

• Pull the rotor straight off the hub.
• If it’s stuck, tap around the rotor hat with a hammer you can safely use (do not hit wheel studs). If needed, clean rust at the hub with a wire brush.
• Clean the hub face using a wire brush and spray with brake cleaner.

Step 6: Install the new rotor

• Clean the new rotor friction surfaces using brake cleaner (removes packing oil).
• Install the rotor onto the hub.
• Hold the rotor flush by threading on one lug nut finger-tight (use your existing lug nut).

Step 7: Prep the bracket and install new pad hardware

• Remove old pad clips from the bracket using a flathead screwdriver.
• Clean the bracket pad “tracks” where the clips sit using a wire brush.
• Install new clips from the rear brake pad hardware kit.
• Apply a thin layer of brake lubricant (silicone brake grease) where pads slide on the clips (keep grease off rotor/pad friction surfaces).

Step 8: Compress the caliper piston

• With EPB in maintenance mode (if equipped), compress the caliper piston slowly using a C-clamp (6").
• Go slow and steady; stop if it binds hard. Fast compression can damage seals.

Step 9: Reinstall bracket, pads, and caliper

• Reinstall the caliper bracket and tighten bolts using a 17mm socket and torque wrench (1/2" drive). Torque to 90 Nm (66 ft-lbs)
• Install the new pads into the bracket.
• Reinstall the caliper over the pads and install slide pin bolts using a 14mm socket and torque wrench (3/8" drive). Torque to 34 Nm (25 ft-lbs)

Step 10: Reinstall wheels

• Reinstall the wheels and hand-thread all lug nuts.
• Lower the vehicle off the jack stands (rated 3-ton minimum) using the floor jack (rated 3-ton minimum).
• Tighten lug nuts in a star pattern using a torque wrench (1/2" drive). Torque to 103 Nm (76 ft-lbs)

Step 11: Exit EPB maintenance mode (if equipped)

• Use the scan tool to end EPB maintenance mode and confirm the system returns to normal operation.

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✅ After Repair

• 🧪 Pump the brake pedal 10–15 times until it feels firm (this seats the pads against the rotors).
• 🧪 Start your Highlander and confirm normal brake pedal feel before moving.
• 🧪 Test the parking brake function (especially if EPB equipped).
• 🧪 Do a careful road test: slow stops first, then gradually normal stops.
• 🧪 Pad bed-in (recommended): perform 6–8 moderate stops from 40–10 mph, with short cool-down drives between stops.

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💰 DIY vs Shop Cost

Shop Cost: $650-$1,050 (parts + labor)

DIY Cost: $220-$450 (parts only)

You Save: $430-$600 by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 2-3 hours.

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🎯 Ready to get started?

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