Year	Make	Model	Engine
2005	Toyota	Tacoma	2.7L L4, 4.0L V6
2006	Toyota	Tacoma	2.7L L4, 4.0L V6
2007	Toyota	Tacoma	2.7L L4, 4.0L V6
2008	Toyota	Tacoma	2.7L L4, 4.0L V6
2009	Toyota	Tacoma	2.7L L4, 4.0L V6
2010	Toyota	Tacoma	2.7L L4, 4.0L V6

*Verify your vehicle has four piston calipers, as some Tacoma's have single piston sliding calipers which is not covered in the technical blog.

Hardware:

📷#imagesbykak

HAWK Performance brake pads and rotors were used for this brake system upgrade on a 2005 Toyota Tacoma TRD Offroad 4WD. HAWK is a brand of Carlisle Brake & Friction which is headquarter in Medina, Ohio. Their brake pads are "designed, engineered and produced in the United States" [1]. We selected their LTS (Light Truck & SUV) line of pads for several reasons. The pads offer great initial response, increased stopping power with their high friction coefficent, superior wear and overall pad life, and low dust output.[2] This can all be attributed to HAWK's ferro-carbon pad design, which as the name implies is a compound of ferrous (iron) and carbon materials.

HIGH PERFORMANCE

Item	PN:	Mfr.	Vendor A	Vendor B	Notes
Brake Pads	HB490Y.665	HAWK	Tire Rack	Amazon	Made in U.S.A
Brake Rotors	HTC4918	HAWK	Tire Rack	Amazon	Cross-Drilled / Slotted

Photos:

Parts List:

Parts List

Vehicle			Repair ID			Kohlibuilt.com
2005 Toyota Tacoma - 2nd Gen			Front Brake & Pads Rotor			Kohlibuilt.com
Required Parts
Item	PN:	Qty.	Mfr.	Vendor A	Vendor B	Notes
Brake Pads	HB490Y.665	1 Set	HAWK Performance	Tire Rack	Amazon	Made in U.S.A
Brake Rotors	HTC4918	1 Set	HAWK Performance	Tire Rack	Amazon	Cross-Drilled and Slotted
DOT 4 Brake Fluid	HP520	500mL	HAWK Performance	Tire Rack	Amazon	DOT 4 brake fluid that is above OE spec
Synthetic Brake Grease	SL3301	2.5 oz	CRC	NAPA	Amazon	"Moly" Graphite & PTFE
Specialty Tools
Item	PN:	Qty.	Mfr.	Vendor A	Vendor B	Notes
M8 x 1.25 mm	90447A130	2	DIN 933 SPEC	McMASTER-CARR	N/A	High-Strength Class 10.9
Brake Hub Cleaning Kit	21758	1	3M	JB Tools	NAPA	Made in U.S.A
Brake Caliper Press	279	1	Lang Tools	JB Tools	NAPA	Made in U.S.A
Caliper Hanger	51600	1 Set	Titan	JB Tool	O'Reilly Auto Parts
Dial Indicator	AT205661	1	Turlen	Amazon		0.0005" graduation
Standard Tools
Item	PN:	Qty.	Mfr.	Vendor A	Vendor B	Notes
Long Nose Pliers
↪ Option A	2501160SBA	1	KNIPEX	JB Tools	Amazon	Made in Germany
↪ Option B	3017	1	CHANNELLOCK	JB Tools	Amazon	Made in U.S.A
Dead-Blow Hammer
↪ Option A	JHWJHW-24	1	Williams	Amazon		Made in U.S.A, a Snap-On Brand
↪ Option B	23050	1	ARES	Amazon		Made in U.S.A
17mm Combination Wrench	88517	1	SK Tools	Amazon		Made in U.S.A,Long Handle
12mm Combination Wrench	88512	1	SK Tools	Amazon		Made in U.S.A,Long Handle

Procedure:

DISCLAIMER:

In the performance of repairs and maintenance, the methodology set out in this technical manual is highly effective. However, this technical manual should not be regarded as the substitute for a qualified technician. Severe injury, damage or loss could occur if only this technical manual is relied upon by inexperienced or unqualified technicians.

Although every effort has been made to ensure that the information provided in this technical manual is accurate, KohliBuilt.com and the authors are not responsible for any loss, damage or injury which may result from the information supplied.

WARNING:

CAUTION:

1. SAFELY LIFT & SUPPORT THE VEHICLE

View referance graphic for lift points.

NOTICE: If removing wheel lug nuts with a wrench, loosen but DO NOT remove lugs before lifting.

2. REMOVE FRONT WHEELS

3. REMOVE FRONT DISC ANTI-RATTLE SPRING & PIN ASSEMBLY

Remove the two retainer clips from the support pins.
Remove the support pins.
Remove the anti-rattle spring.

4. REMOVE BRAKE PADS FROM CALIPER

5. REMOVE THE DISC BRAKE CALIPER

Remove the two mounting bolts from the disc brake caliper.
Mounting bolts are 17mm hex head.

6. REMOVE THE DISC BRAKE LINE BRACKET BOLT

Mounting bolts are 12mm hex head.

7. SUPPORT BRAKE CALIPER

DO NOT let the caliper hang from brake line.

8. REMOVE ROTOR

PRO TIP: The rotor can develope rust between the rotor's mounting surface and the hub's face, which can make the removal of the rotor dificult. Most rotors will have two tapped holes which a bolt can be treaded into and force the rotor off the hub. For this Tacoma the bolt size is M8-1.25.

Item	PN:	Mfr.	Vendor
High-Strength Class 10.9 M8 x 1.25 mm	90447A130	DIN 933 SPEC	McMASTER-CARR

9. REMOVE RUST FROM AND CLEAN HUB FACE

Rust and debris can cause lateral runout issues, leading to brake vibrations.

10. INSTALL NEW ROTOR

PRO TIP: New rotors usually come from the manufacturer with a coating of oil to help prevent corrosion (rusting) during shipment and stockroom storage. This coating must be removed to ensure maximum friction coefficient between the brake pads and rotors. Failure to remove this coating or any other oil/contaminates could result in unsafe brake system operation. To remove them, simply clean the rotors with a quality brake cleaner solvent and wipe them away with a towel or cloth. Alternately, hot soapy water can also be used.

11. INSPECT ROTOR LATERAL RUNOUT

Toyota OEM Maximum rotor runout: 0.002" (0.05mm) [3]

Item	PN:	Mfr.	Vendor	Note
Dial Indicator	AT205661	Türlen	Amazon	0.0005"

12. RESET BRAKE CALIPER PISTONS

Remove the brake master cylinder fluid reservoir's cap.
Using a brake caliper press tool or c-clamp press the caliper's piston back into the fully seated position.
Install the brake master cylinder fluid reservoir's cap.

Item	PN:	Mfr.	Vendor A	Vendor B	Note
Brake Caliper Press	Lang Tools 279	Lang Tools	JB Tools	NAPA	Made in U.S.A

13. INSTALL BRAKE CALIPER ASSEMBLY

The assembly is installed with two bolts.

Toyota OEM Torque: 91 ft·lbf [3]

14. INSTALL THE DISC BRAKE LINE BRACKET BOLT

Mounting bolt is 12mm hex head.

Toyota OEM Torque: 21 ft·lbf [3]

15. INSTALL ANTI SQUEAL SHIMS

Some manufacturer's brake pads come with anti squeal shims pre-installed.
Apply high temp brake grease between the back side of the brake pad and the anti squeal shim prior to installation, refer to the pad assembly illustration.
Apply high temp brake grease to the outside of the anti squeal shims, refer to the pad assembly illustration.

NOTICE: The brake pad friction surface (blue area in pad assembly illustration) and the brake disk rotor should NOT have any oil or grease on them.

16. INSTALL BRAKE PADS

Item	PN:	Mfr.	Vendor A	Vendor B	Note
Synthetic Brake Grease	SL3301	CRC	NAPA	Amazon	"Moly" Graphite PTFE

17. INSTALL FRONT DISC ANTI-RATTLE SPRING & PIN ASSEMBLY

Install anti-rattle spring

Toyota OEM PN: 47748-0C010

Install support pins

Toyota OEM PN: 90240-06158

Install two retainer clips into the support pins

Toyota OEM PN: 47749-35040

18. INSPECT BRAKE FLUID LEVEL

Fluid: FMVSS No. 116 DOT3 or better

NOTICE: Do not use silicone based or DOT 5 brake fluid.

NOTICE: Brake fluid can damage painted surfaces and spilled fuild should be promptly washed off.

19. DEPRESS OR PUMP BRAKE PEDAL SEVERAL TIMES

Ensure there is a stiff brake pedal, if not this could be an indication of air in the brake lines.

NOTICE: Depressing the vehicle's brake pedal with the reservoir cap not installed can cause fluid to spray.

20. INSPECT BRAKE FLUID LEVEL

Ensure the brake fluid level is between the MIN and MAX indicators on the brake fluid reservoir.

PRO TIP: If any work was done that required the brake fluid system to be opened or if air in the system is suspected, the brake system MUST be bled of air.

Item	PN:	Mfr.	Vendor A	Vendor B	Note
DOT 4 Brake Fluid	HP520	HAWK Performance	Tire Rack	Amazon	DOT 4 brake fluid that is above OE spec

21. INSTALL FRONT WHEELS

22. LOWER VEHICLE

23. TORQUE FRONT WHEEL LUG NUTS

Toyota OEM Torque: 84 ft·lbf [3]

24. BED-IN BRAKE PADS

Follow manufacturer's bed-in procedures: www.hawkperformance.com/how-to

REFERENCES:

[1] why hawk. (2022, August 18). Hawk Performance. https://www.hawkperformance.com/why-hawk
[2] LTS. (2022, July 7). Hawk Performance. https://www.hawkperformance.com/lts
[3] Toyota Motor Corporation. (2004). 2005 Toyota Tacoma Repair Manual: Pub. No. RM1162U3 (Vol. 3).

AFFILIATE DISCLAIMER:

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