🔧 Highlander - Rear Brake Pad & Rotor Replacement

This repair replaces the rear brake pads and rear brake rotors on your Highlander. The rear brakes use an electronic parking brake, so the parking brake must be put into service mode before removing the calipers.

Difficulty Level: Intermediate | Estimated Time: 2-3 hours

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⚠️ Safety & Precautions

• ⚠️ Your Highlander is a hybrid. Do not touch orange high-voltage cables or hybrid battery components.
• ⚠️ Do not turn the ignition ON while the rear calipers are removed.
• ⚠️ The electronic parking brake must be retracted before brake service.
• ⚠️ Support the vehicle with jack stands. Never work under a vehicle supported only by a jack.
• ⚠️ Wear safety glasses and gloves. Brake dust and cleaner can irritate skin and eyes.
• ⚠️ Do not press the brake pedal while the caliper is off the rotor.

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🔧 Required Tools

You'll need the following tools for this repair:

• 10mm wrench
• 14mm socket
• 17mm socket
• 21mm socket
• 3/8-inch ratchet
• 1/2-inch breaker bar
• Torque wrench rated to 100 ft-lbs
• Rear brake caliper piston compressor tool
• Flat-blade screwdriver
• Rubber mallet
• Wire brush
• Bungee cord
• Floor jack rated 3-ton minimum
• Jack stands rated 3-ton minimum
• Wheel chocks
• Safety glasses
• Nitrile gloves

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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 hardware kit - Qty: 1
• Brake cleaner - Qty: 1 can
• High-temperature brake lubricant - Qty: 1 tube

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📋 Before You Begin

• Park your Highlander on level ground.
• Do not apply the parking brake before lifting the rear of the vehicle.
• Place wheel chocks in front of the front wheels.
• Open the hood and remove the brake fluid reservoir cap so the caliper pistons can retract more easily.
• If brake fluid is near the MAX line, remove a small amount with a clean suction tool to prevent overflow.
• Put the electronic parking brake into service mode using the switch sequence below before removing rear brake parts.
• A caliper piston compressor pushes the brake piston back into the caliper so new thicker pads fit over the rotor.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Enter Rear Brake Service Mode

• Sit in the driver seat with the doors closed.
• Make sure the parking brake is released.
• Press the brake pedal and turn the ignition ON without starting the engine.
• Use the parking brake switch and perform this sequence: pull up 3 times, then push down 3 times.
• Hold the parking brake switch down for about 5 seconds.
• Listen for the rear parking brake motors to retract.
• Confirm the parking brake warning light is flashing or a service-mode message appears.
• Do not skip this step.

Step 2: Loosen the Rear Wheel Lug Nuts

• Use the 21mm socket and 1/2-inch breaker bar to loosen each rear wheel lug nut about half a turn.
• Do this while the tires are still on the ground so the wheels do not spin.

Step 3: Lift and Support the Rear of the Vehicle

• Use the floor jack rated 3-ton minimum at the rear center jacking point.
• Place jack stands rated 3-ton minimum under the rear side pinch welds or approved rear support points.
• Lower the vehicle gently onto the jack stands.
• Use wheel chocks at the front wheels.
• Gently shake the vehicle to make sure it is stable.

Step 4: Remove the Rear Wheels

• Use the 21mm socket and 3/8-inch ratchet to remove the loosened lug nuts.
• Remove both rear wheels and set them aside flat.

Step 5: Remove the Rear Caliper

• Use the 14mm socket and 3/8-inch ratchet to remove the two rear caliper slide pin bolts.
• Lift the caliper off the pads and rotor.
• Use the bungee cord to hang the caliper from the suspension spring or control arm.
• Do not let the caliper hang by the rubber brake hose.
• A slide pin lets the caliper move side to side as the pads wear.

Step 6: Remove the Old Rear Brake Pads

• Use the flat-blade screwdriver to gently pry the old pads out of the caliper bracket.
• Note the position of any wear indicator clips before removal.
• Remove the old stainless pad clips from the bracket by hand or with the flat-blade screwdriver.

Step 7: Remove the Rear Caliper Bracket

• Use the 17mm socket and 1/2-inch breaker bar to remove the two caliper bracket bolts.
• Remove the caliper bracket and set it on a clean surface.
• Inspect the slide pins. They should move smoothly by hand.

Step 8: Remove the Rear Rotor

• Pull the rotor straight off the hub by hand.
• If the rotor is stuck, tap around the rotor hat with the rubber mallet.
• If it still will not move, make sure the parking brake service mode was completed and the parking brake is fully released.
• Do not pry hard against the dust shield behind the rotor.

Step 9: Clean the Hub and Bracket

• Use the wire brush to clean rust from the wheel hub face.
• Use brake cleaner on the hub and caliper bracket.
• Use the wire brush to clean the pad clip contact areas on the bracket.
• A clean hub prevents brake vibration.

Step 10: Install the New Rear Rotor

• Clean both sides of the new rotor with brake cleaner.
• Slide the rotor onto the hub by hand.
• Install one lug nut backward by hand to hold the rotor flat against the hub.

Step 11: Reinstall the Caliper Bracket

• Position the caliper bracket over the rotor.
• Start both bracket bolts by hand to avoid cross-threading.
• Use the 17mm socket and torque wrench rated to 100 ft-lbs to tighten the bracket bolts to Torque to 88 Nm (65 ft-lbs).

Step 12: Install New Brake Hardware and Pads

• Install the new stainless pad clips from the rear brake hardware kit into the caliper bracket by hand.
• Apply a thin layer of high-temperature brake lubricant only where the pad ears contact the clips.
• Do not get grease on the pad friction material or rotor surface.
• Slide the new rear brake pads into the bracket by hand.
• The friction material must face the rotor.

Step 13: Compress the Rear Caliper Piston

• Use the rear brake caliper piston compressor tool to slowly push the caliper piston straight back into the caliper.
• Go slowly and watch the brake fluid reservoir so it does not overflow.
• If the piston will not retract smoothly, stop and recheck that the electronic parking brake is in service mode.

Step 14: Reinstall the Rear Caliper

• Place the caliper over the new brake pads.
• Start the two slide pin bolts by hand.
• Use the 14mm socket and torque wrench rated to 100 ft-lbs to tighten the slide pin bolts to Torque to 34 Nm (25 ft-lbs).

Step 15: Repeat on the Other Side

• Repeat Steps 5 through 14 on the opposite rear brake.
• Replace rear brake pads and rotors in pairs for even braking.

Step 16: Reinstall the Rear Wheels

• Remove the temporary lug nut holding each rotor.
• Install the wheels by hand.
• Use the 21mm socket and 3/8-inch ratchet to snug the lug nuts in a star pattern.

Step 17: Lower the Vehicle and Torque the Lug Nuts

• Use the floor jack rated 3-ton minimum to lift slightly and remove the jack stands.
• Lower the vehicle until the tires touch the ground.
• Use the 21mm socket and torque wrench rated to 100 ft-lbs to tighten the lug nuts in a star pattern to Torque to 103 Nm (76 ft-lbs).

Step 18: Exit Rear Brake Service Mode

• Press the brake pedal several times until it feels firm.
• Turn the ignition ON without starting the engine.
• Use the parking brake switch and perform this sequence: push down 3 times, then pull up 3 times.
• Hold the parking brake switch up for about 5 seconds.
• Listen for the parking brake motors to apply and initialize.
• Turn the ignition OFF, then ON, and confirm the parking brake warning light is off.

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✅ After Repair

• Check the brake fluid level and reinstall the reservoir cap.
• Press the brake pedal several times before moving the vehicle.
• Test the electronic parking brake. Apply and release it once.
• Drive slowly in a safe area and verify normal brake pedal feel.
• Bed in the new pads with 8-10 moderate stops from about 30 mph to 5 mph. Do not come to a full stop with hot brakes if possible.
• Recheck lug nut torque after the first short drive: Torque to 103 Nm (76 ft-lbs).
• If warning lights remain on, a scan tool may be needed to clear electronic parking brake or brake system codes.

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💰 DIY vs Shop Cost

Shop Cost: $450-$750 (parts + labor)

DIY Cost: $140-$300 (parts only)

You Save: $310-$450 by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 1.5-2.0 hours.

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