Part# 1055208 – 2005+ Tacoma Rear Disc Brake Conversion Kit

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Installation Instructions



Step 1: Safely support the vehicle by the rear axle housing so the rear wheels are off the ground and free to rotate. Remove the rear wheels and brake drums from the rear axle.

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Step 2: Disconnect the brake line from the wheel cylinder and the tab mounted on the axle. Disconnect the ABS wire and remove the ABS sensor from the bearing housing.

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Step 3: Disassemble the brake drum components from the backing plate and disconnect the E-brake cable. Completely remove the E-brake cable from the vehicle or secure it out of the way on the frame.

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Step 4: Remove the (4) nuts holding the axle and backing plate assembly to the axle housing.

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Step 5: Remove the axle and backing plate assembly from the axle housing. A small amount of gear oil may leak from the housing so have an oil pan ready to catch the fluid.

Step6: Use a soft face hammer and remove the (4) mount­ing studs as shown. If you do not want to re-use your backing plate skip to Step 9. If you do want to re-use your backing plate remove the bearing retaining ring from the axle.

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Step 7: In order to remove the brake drum backing plate (for re-use) you will need to use a press and a bearing puller to remove the axle shaft from the bearing housing according to the appropriate Toyota service manual. If you do not have the correct tools or mechanical experience to complete this step we advise that you find a qualified automotive shop or an authorized Trail-Gear installer to complete this step for you in a safe and professional manner. If you have any questions about this step, please call Trail-Gear tech support at 559.252.4950.

Step 8: Once the backing plate is removed, reassemble the axle and bearing housing according to the appropriate Toyota service manual.

Step 9: If you do not wish to re-use your brake drum backing plate use an angle grinder equipped with a cutting wheel and cut the backing plate as shown. Use care not to nick or damage the bearing housing, bearings, or axle shaft. If you are unable to cut all the way to the center of the backing plate cut as far as you can then bend the backing plate back and forth to break the remaining material.

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Step 10: Clean the axle shaft and bearing to ensure they are free from grinder dust or any other contaminants.

Step 11: If you are installing new seals (recommended), remove the old a-ring and oil seal from the axle housing. Install the new a-ring and oil seal follow­ing the appropriate Toyota service manual.

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Step 12: Insert the axle shaft and bearing housing assembly back into the axle housing. Ensure that the splines on the axle shaft properly engage the splines on your differential before seating the bearing housing against the axle housing flange. There should be little effort needed to slide the axle splines into the differential. Ensure that the orientation of the ABS sensor mounting stud is the same as it was before.

Step 13: Using (3) M10X60MM bolts and (3) M10 lock nuts install the brake caliper mounting bracket on the back side of the axle flange. The bracket needs to be in the 2 o'clock position (on the driver's side), or above the axle to the rear of the vehicle. The brake line enters the caliper from the bottom and the bleeder is on the top on both sides of the vehicle.

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Step 14: Install (1) M10X55MM bolt and (1) M10 lock nut in the remaining hole. Torque all M10 bolts to 45-50 ft-lbs.

Step 15: Place the rotor over the wheel studs and install the caliper with the special fasteners supplied with the caliper. There is a right hand and a left hand caliper. The left side (driver's side) is shown, brake line on the bottom, bleeder on the top. Torque the caliper bolts to 30-35 ft-lbs.

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Step 16: Install the provided brake lines using the banjo bolt and (2) copper washers (1 per side) that were supplied with the caliper. The bend in the fitting needs to be facing up (away from the bolt head) so that the brake line can be routed over the leaf spring and on top of the axle.

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Step17: Install the other end of the brake line in the axle mounted tab closest to the caliper.

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Step18: Repeat this process for the other side of the vehicle.

Step 19: Completely bleed the brakes so that all air is removed from the system and test for leaks. It may be necessary to add more brake fluid to the brake fluid reservoir during this process.

Step 20: Install the rear wheels and torque all lug nuts.

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