🔧 Prius - Rear Brake Pad and Rotor Replacement

This repair replaces the rear brake pads and both rear rotors on your Prius. The rear caliper pistons must be rotated while being pushed inward because the parking-brake mechanism is built into each caliper.

Difficulty Level: Intermediate | Estimated Time: 2.5-4 hours

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⚠️ Safety & Precautions

• Your Prius uses an electrically pressurized brake system. Keep the key fob away from the vehicle and do not open doors or press the brake pedal while a caliper is removed.
• Disconnect the negative terminal of the 12-volt battery before removing either caliper. The high-voltage hybrid battery does not need to be disconnected.
• Release the foot-operated parking brake before beginning. Chock both front wheels securely.
• Never work under a vehicle supported only by a floor jack. Use jack stands at the approved rear support points.
• Brake dust may be harmful. Do not blow it away with compressed air.
• Brake fluid damages paint. Wipe spills immediately and do not allow the reservoir to overflow while retracting the pistons.
• Replace pads and rotors on both rear wheels so braking remains balanced.

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🔧 Required Tools

You'll need the following tools for this repair:

• 21mm deep socket
• 14mm socket
• 17mm socket
• 3/8-inch drive ratchet
• 1/2-inch drive breaker bar
• Torque wrench rated 10-150 Nm
• Rear brake piston wind-back tool (specialty)
• 8mm hex-bit socket
• M8 x 1.25 rotor-removal bolts (specialty)
• Small flat-blade screwdriver
• Medium wire brush
• Rubber mallet
• Caliper hanger
• Floor jack rated 2-ton minimum
• Jack stands rated 2-ton minimum
• Wheel chocks
• Brake-fluid syringe
• Disposable 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 - Replace in pairs - Qty: 2
• Rear brake hardware kit - Qty: 1
• Rear caliper slide-pin boots - Qty: 4 if damaged
• High-temperature silicone brake grease - Qty: 1
• Brake cleaner - Qty: 2 cans
• DOT 3 brake fluid - Qty: 1 small sealed container if needed

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📋 Before You Begin

• Park your Prius on firm, level ground. Select Park, switch the vehicle off, and release the parking brake completely.
• Place wheel chocks tightly against both sides of the front tires.
• Open the hatch and remove the right-side luggage trim access panel to reach the 12-volt battery.
• Keep the key fob at least 5 metres away so the brake system cannot wake unexpectedly.
• Use a 10mm socket to disconnect the negative 12-volt battery terminal. Insulate the cable so it cannot touch the terminal, then wait at least two minutes.
• Check the brake-fluid reservoir. If it is at the maximum line, use a brake-fluid syringe to remove a small amount before retracting the pistons.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Loosen the rear wheel nuts

• Use a 21mm deep socket and 1/2-inch breaker bar to loosen each rear wheel nut about one-half turn.
• Do not remove the wheel nuts while the vehicle is still on the ground.

Step 2: Raise and support the rear

• Use the 2-ton floor jack at the reinforced rear-center lifting point beneath the vehicle.
• Place the 2-ton jack stands beneath the approved left and right rear support points.
• Lower the vehicle gently onto the stands and confirm it is stable before continuing.

Step 3: Remove both rear wheels

• Use the 21mm deep socket and 3/8-inch ratchet to remove the wheel nuts.
• Remove both wheels and place them flat away from the work area.

Step 4: Remove the rear caliper

• Work on one side at a time so the assembled side remains available as a reference.
• Use a 14mm socket and 3/8-inch ratchet to remove the upper and lower caliper slide-pin bolts.
• Lift the caliper away from the pads. Use the caliper hanger to suspend it from the suspension.
• Do not let the caliper hang by its flexible brake hose.

Step 5: Remove the old pads and hardware

• Pull the inner and outer pads out of the caliper bracket by hand.
• Use a small flat-blade screwdriver to remove the stainless-steel pad-support clips.
• Note the position of the inner pad’s locating pin and wear indicator before discarding the pads.

Step 6: Remove the caliper bracket

• Use a 17mm socket and 1/2-inch breaker bar to remove the two caliper-bracket bolts.
• Remove the bracket and place it on a clean work surface.

Step 7: Remove the old rotor

• Pull the rotor straight off the hub.
• If it is rusted in place, thread the two M8 x 1.25 rotor-removal bolts evenly into the rotor’s extraction holes using a 13mm socket and 3/8-inch ratchet.
• Tighten the extraction bolts a little at a time, alternating between them until the rotor releases.
• If necessary, tap the rotor hat lightly with a rubber mallet. Do not strike the wheel studs.

Step 8: Clean and inspect the hub

• Use the medium wire brush to remove rust from the hub face and rotor-centering ring.
• Spray brake cleaner onto a clean disposable cloth and wipe the hub.
• Make sure the hub face is smooth. Rust trapped behind the rotor can cause pedal pulsation.

Step 9: Install the new rotor

• Use brake cleaner and a clean disposable cloth to remove the protective coating from both friction surfaces of the new rotor.
• Slide the rotor fully onto the hub.
• Temporarily install two wheel nuts by hand to hold the rotor flat while assembling the brakes.

Step 10: Service the caliper bracket

• Pull each slide pin from the bracket by hand and inspect it for rust, scoring, or torn rubber boots.
• Use a clean disposable cloth to wipe the pins. Apply a thin coat of high-temperature silicone brake grease before reinstalling them.
• Use the medium wire brush to clean the hardware seating areas.
• Press the new pad-support clips into the bracket by hand. Do not put grease on the rotor or pad friction material.

Step 11: Reinstall the caliper bracket

• Position the bracket over the new rotor and start both bolts by hand.
• Use the 17mm socket and torque wrench to tighten both bracket bolts to 57 Nm (42 ft-lbs).

Step 12: Retract and align the caliper piston

• Fit the rear brake piston wind-back tool into the grooves on the piston face. A wind-back tool pushes and rotates the piston at the same time.
• Rotate the piston clockwise while applying steady inward pressure until it is fully seated.
• Watch the brake-fluid reservoir and use the brake-fluid syringe if the level approaches the top.
• Finish with a piston groove aligned to accept the locating pin on the back of the inner pad. The pin must sit inside the groove, not on a raised section.
• Inspect the piston dust boot and make sure it is not twisted or pinched.
• Turn slowly to protect the piston boot.

Step 13: Install the new pads

• Apply a very thin coat of high-temperature silicone brake grease to the pad ears where they contact the support clips.
• Install the inner and outer pads into the bracket by hand.
• Keep all grease and fingerprints off the pad friction surfaces and rotor faces.

Step 14: Reinstall the caliper

• Remove the caliper from the hanger and lower it over the new pads.
• Confirm the inner pad’s locating pin enters the aligned piston groove.
• Start both slide-pin bolts by hand to prevent cross-threading.
• Use the 14mm socket and torque wrench to tighten the slide-pin bolts to 34 Nm (25 ft-lbs).
• Make sure neither slide-pin boot is twisted.

Step 15: Repeat on the opposite side

• Use the same tools and procedure to replace the pads and rotor on the other rear wheel.
• Compare both completed sides and confirm the hoses, boots, clips, and pad positions match.

Step 16: Reinstall the wheels

• Remove the temporary wheel nuts using the 21mm deep socket and 3/8-inch ratchet.
• Install each wheel and start all wheel nuts by hand.
• Use the 21mm deep socket and 3/8-inch ratchet to snug the nuts in a star pattern.
• Use the floor jack to raise the vehicle, remove the jack stands, and lower the tires onto the ground.
• Use the 21mm deep socket and torque wrench to tighten the wheel nuts in a star pattern to 103 Nm (76 ft-lbs).

Step 17: Restore the brake system

• Use the 10mm socket to reconnect and secure the negative 12-volt battery terminal.
• Without selecting a gear, press the brake pedal slowly several times until it becomes firm.
• Check the brake-fluid reservoir and adjust it to between the minimum and maximum marks using fresh DOT 3 brake fluid if needed.
• Start the vehicle in READY mode and confirm the ABS, brake, and master-warning lights turn off normally.

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✅ After Repair

• Apply and release the foot-operated parking brake several times. Confirm both rear wheels hold and release normally.
• Inspect both calipers and brake hoses for leaks while the brake pedal is held firmly.
• At walking speed, test the brakes in a safe, traffic-free area before normal driving.
• Bed in the pads with 8-10 moderate stops from approximately 50 km/h to 15 km/h. Allow about 30 seconds between stops and avoid coming to a complete stop with hot brakes.
• Avoid hard braking for the first 300 km unless needed for safety.
• Recheck the wheel-nut torque after approximately 80-100 km.
• If the pedal remains soft, a warning light stays on, or fluid leaked during the repair, do not drive the vehicle. The electronically controlled brake system requires proper bleeding with a Toyota-compatible scan tool.

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💰 DIY vs Shop Cost

Shop Cost: ₹18,000-₹32,000 (parts + labor)

DIY Cost: ₹8,000-₹17,000 (parts only)

You Save: Approximately ₹10,000-₹15,000 by doing it yourself!

Local labor and imported US-market Prius parts pricing vary. This repair takes a shop approximately 2-3 hours.

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