Brake Disc Caliper Problems of Toyota FJ Cruiser

During 2019-2020 state inspection of 2007 Fj Cruiser with 78000 miles by dealer was told that frame is so rusted that it probably would not pass the next inspection. Explanation given was that Toyota does not make their frames as thick as other makes. This vehicle was used as a daily driver, not much off-road and no serious off-roading. I work from home, so most years less than 5000 miles driven. Also have had to replace front brake calipers for the past 3 years.

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Hello, Toyota calipers and caliper pistons have a problem. The pistons or calipers are corroding and causing delayed employment of braking on that caliper. Understand that the calipers that are working correctly will "pull" to the side they are on and the caliper that has a problem will have a delayed engagement. This is extremely dangerous. The "good" caliper causes the car to pull to that side, then the "bad" caliper engages pulling the car back the other way. When the brakes are released, the "good" caliper lets go and the "bad" caliper releases a few seconds later. Understand that this can happen on any of the four calipers front or rear. The combinations of good and bad calipers can cause the car to zig zag left or right unpridictably, pulling left or right, and if the driver is not ready for it, can cause a big problem controlling the car. Hard to explain the complexity of the various braking responses you can get with this problem, but check the comments on the internet and know that there are thousands of people with issues with Fj Cruisers, four runners etc. I have had three calipers replaced under warranty, but the problem is returning. Toyota knows they have a problem, but as usual, no public acknowledgement. Please do something about it. You can contact me anytime, gary galleher 4225 covert road, perrysville, ohio 44864 419-938-0252. This is a problem and please look into it.

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Brake caliper and brake caliper pistons bind in caliper bore causing the vehicle to pull to one side or the other depending on which side the problem is. When the brakes are applied, the "good" calipers do their job, but the bad caliper pistons are momentarily stuck and this causes the car to pull to the good side as the brakes are applied, then a moment later the "bad" brake pistons let loose and the car pulls back the other way. Also then as the pistons are bound, when the brakes are released, the good side pistons retract, but the bad side bind on return, so pulling to the bad side. This is most noticed on the front brakes but also occur on the back. Note that the "bad" side on the back may not be the same side as "bad" on the front, causing a zig-zag type pulling , front one way, back the other and can be very unptedictable, particularly when sudden or "panic" braking occurs. I purchased an extended warranty with the car and Toyota authorized and the dealer did replace three complete calipers no charge under my extended Toyota warranty. However subsequent complaints brought the regional service rep to a meeting at my request where we went to an empty parking lot and conducted "panic" stops several times at 35 mph and one at 40 mph with not duplication of my complaints. I am suspicious that the panic stopping is a way to get what would be called a "proportioning control valve" to un-stick. This valve as I call it is a device that balances brake fluid pressure to all four calipers in an equal criss-cross pressure so all calipers are getting the same pressure unlike old fassioned single or double systems from back in the day. I can't verify this is a "secret" service fix for unbalanced braking, but now some months after my caliper replacements, the calipers are beginning to exhibit the same problem and I'm out of warranty. Obviously there is a problem with the design.

Bad vibration when applying the brakes. End result was the rotors,brake pads, and both calipers had to be replaced!! an $800. 00 bill! dealer stated it was probably due to road salt errosion!! these vehicles are promoted as off-road/4wd go anywhere vehicles! I have never had to replace calipers on any vehicle I've ever owned. I feel it has to do with the quality of steel they use in these vehicles as I've had to also replace the transmission coolers lines due to rust errosion/leaking of the metal lines! the frame,skid plates and under frame metal are all flaking with rust errosion.