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Problem fitting new brake pads

Discussion in 'Gen 3 Prius Care, Maintenance & Troubleshooting' started by harryarcos, Aug 29, 2024 at 8:32 AM.

  1. harryarcos

    harryarcos Junior Member

    Joined:
    Feb 8, 2017
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    Location:
    London
    Vehicle:
    2004 Prius
    Model:
    N/A
    I could not find anything where the recent problems I experienced fitting new brake pads has been mentioned before, so I hope this helps someone to save a few hours struggling with the job.

    Having decided to change my Gen 2 Prius for a 2010 model, I travelled less than 20 miles before the grinding of metal on metal made me aware that perhaps the "well looked after" car had not had a recent service. It was clearly a job that needed doing urgently, but taking the old pads out proved to be more difficult than it should have been. It was then impossible to fit the new ones, leading me to wonder if the correct pads were in the box.

    The reason for the problem was that there was a build up of rust below the clips which the pads fit into and this had made the housing too tight. Once I realised this and managed to grind it down using a 'Dremel' I was able to complete the job.

    I had intended to replace the brake fluid with the "Not using Techstream" method. However, I could not get it to work and never got the brake warning light to blink. The English on the sheet is not perfect, so I am not sure where it went wrong. I normally use a brake hose clamp and open the bleed screw connected to a tube etc. when returning the cylinder into the caliper and this worked ok on the Gen 3 with no warning lights after the job was done.
     
    StarCaller likes this.
  2. ColoradoBoo

    ColoradoBoo Senior Member

    Joined:
    Jul 19, 2019
    991
    656
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    Location:
    Monument, Colorado USA
    Vehicle:
    2017 Prius
    Model:
    Two
    Dang, pretty scary...sorry you've had such a hard time! I've never done a brake job on a hybrid and my wife's 2017 is our oldest one so wondering if I just should let my dealer handle the job, when the time comes.
    I have had rust on the calipers which has to be sanded and cleaned before the new shoes would fit, and slide up and down a bit like they are supposed to but never anything too egregious.
    Keep us updated!