The Problem
The customer complained of a grinding noise when braking, steering wheel vibration at highway speeds, and the brake pedal feeling 'spongy'. They had been putting off the repair for several weeks.
- Loud metallic grinding noise when braking
- Steering wheel vibration when braking above 80 km/h
- Brake pedal feeling soft and spongy
- Vehicle pulling slightly to the left under braking
- Increased stopping distance noticed in traffic
Diagnosis
A thorough brake inspection revealed severely worn front brake pads (metal-on-metal), warped front discs, and a sticking rear caliper. Brake fluid was contaminated and well past its service interval.
- Front brake pads worn to 0mm — backing plates scoring discs
- Front brake discs warped beyond machining tolerance (0.15mm runout vs 0.05mm spec)
- Left rear caliper sticking — uneven pad wear
- Brake fluid contaminated — boiling point below safe threshold
- Brake hoses front left showing micro-cracking
The Repair
Complete front brake replacement with new discs and pads, rear caliper rebuild, brake fluid flush, and replacement of damaged brake hose. Full system bleed and road test.
- Front brake disc and pad replacement (genuine Toyota parts)
- Left rear caliper removed, cleaned, resealed, and refitted
- Rear brake pads replaced for even wear
- Front left brake hose replaced
- Complete brake fluid flush and system bleed
- Brake system pressure test
- Road test at various speeds — braking performance verified
- Final torque check on all brake components
The Result
The Hilux was returned with excellent braking performance. No noise, no vibration, firm pedal feel, and straight-line stopping. The customer was thrilled with the difference.
- Zero noise — smooth, silent braking restored
- No vibration at any speed — discs running true
- Firm, responsive brake pedal feel
- Straight-line stopping — no pulling
- 6-month / 10,000 km warranty on all brake work
Experiencing Similar Issues?
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