2017 Camry-Sticky Front Brake after replacement, stumped

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I did a 4 wheel brake job on my MIL's 2017 Camry over the weekend. For reference, this is pretty close to a base model LE I think(4 cyl, steel wheels, but does have a backup camera). She bought it new and has put 120K on it, most of it around town driving but they usually take it to Florida a few times a year. Rears were down to the rivets with grooved rotors on one side, fronts were at ~2mm I recommended we do them all while I had it. She didn't remember ever having done front brakes(not sure what Toyota factory pads look like) although I know rears have been done at least once.

LF was the the last one I did, and didn't see any unusual signs of wear when I took it all down. Rotor was rusted to the hub(both fronts were) and once off I used a wire brush on an angle grinder, paired with some hand brushing, to clean up the surfaces of the hub. Caliper was cleaned up, retracted without issue(I always retract with the bleeders open-fluid coming out looked fine) and otherwise passed a visual inspection. The bracket was wire wheeled, got all new shims/clips, and slide pins were thoroughly cleaned then greased with Sil-Glyde(and verified for free movement after). Pads move freely and have Permatex ceramic grease on the ears. I do have the "wishbone" springs(not sure what their proper name is) that spread the pads installed, although I've also run it without to make sure they weren't fouling and causing issues.

I took it out for a test drive, and verified all the usuals-it brakes straight and otherwise tracks straight. The only time I had a small amount of pull was accelerating from a stop, but that was to the right and I attributed to torque steer(and it was very subtle). When I was close to home from the test drive, though, someone flagged me down and said my left front wheel was smoking. I pulled over and checked, and sure enough it was and considerably hotter than the right front.

As quickly as I could, I got the car home, jacked it up, and pulled the left front wheel. I cracked the bleeder, partially since the whole thing was still too hot for me to do much else, but also as a quick check for a hose issue(my experience is that if a hose is holding pressure, cracking the bleeder will generally give a spurt of fluid as it's released) and only saw the same sort of small fluid dribble I'd expect if I cracked the bleeder with no pressure on the system.

At this point I've had it apart three times total, twice since the first test drive. The left front brake is still running super hot and obviously is still sticking somewhere along the way, but I'm at a loss as to when/where or what's causing it especially as I can never seem to catch it pulling(and I'd think one sticking that much would cause that). I'm reluctant to just throw parts at it and change the caliper, especially as I'm not super trusting of the rebuilt ones out there. She is planning on selling/trading in the next 6 months, though, so I suppose that could be fine if that's what it needs.

Any thoughts on what else I could possibly check before doing this, though?
 
Jack up the car, pump the brakes and then spin the wheels by hand and compare the left side with the right side. You will get a sense of how hard the bad side holds the wheel.

If the hardware clips are aftermarket they could be the cause.

The caliper, I would pump out the piston pretty far and lift the boot to inspect for rusty spots or dirt.
 
I did a 4 wheel brake job on my MIL's 2017 Camry over the weekend. For reference, this is pretty close to a base model LE I think(4 cyl, steel wheels, but does have a backup camera). She bought it new and has put 120K on it, most of it around town driving but they usually take it to Florida a few times a year. Rears were down to the rivets with grooved rotors on one side, fronts were at ~2mm I recommended we do them all while I had it. She didn't remember ever having done front brakes(not sure what Toyota factory pads look like) although I know rears have been done at least once.

LF was the the last one I did, and didn't see any unusual signs of wear when I took it all down. Rotor was rusted to the hub(both fronts were) and once off I used a wire brush on an angle grinder, paired with some hand brushing, to clean up the surfaces of the hub. Caliper was cleaned up, retracted without issue(I always retract with the bleeders open-fluid coming out looked fine) and otherwise passed a visual inspection. The bracket was wire wheeled, got all new shims/clips, and slide pins were thoroughly cleaned then greased with Sil-Glyde(and verified for free movement after). Pads move freely and have Permatex ceramic grease on the ears. I do have the "wishbone" springs(not sure what their proper name is) that spread the pads installed, although I've also run it without to make sure they weren't fouling and causing issues.

I took it out for a test drive, and verified all the usuals-it brakes straight and otherwise tracks straight. The only time I had a small amount of pull was accelerating from a stop, but that was to the right and I attributed to torque steer(and it was very subtle). When I was close to home from the test drive, though, someone flagged me down and said my left front wheel was smoking. I pulled over and checked, and sure enough it was and considerably hotter than the right front.

As quickly as I could, I got the car home, jacked it up, and pulled the left front wheel. I cracked the bleeder, partially since the whole thing was still too hot for me to do much else, but also as a quick check for a hose issue(my experience is that if a hose is holding pressure, cracking the bleeder will generally give a spurt of fluid as it's released) and only saw the same sort of small fluid dribble I'd expect if I cracked the bleeder with no pressure on the system.

At this point I've had it apart three times total, twice since the first test drive. The left front brake is still running super hot and obviously is still sticking somewhere along the way, but I'm at a loss as to when/where or what's causing it especially as I can never seem to catch it pulling(and I'd think one sticking that much would cause that). I'm reluctant to just throw parts at it and change the caliper, especially as I'm not super trusting of the rebuilt ones out there. She is planning on selling/trading in the next 6 months, though, so I suppose that could be fine if that's what it needs.

Any thoughts on what else I could possibly check before doing this, though?
Try retracting the caliper piston a little then reassemblng the whole assy. Grab the caliper with your hands and really rock it back and forth. You should be able to see movement both ways on the sliders/pad mounts before you pump the pedal to tighten things up. If it's loose before the pump then it must be a binding piston maybe?
 
I wouldn't consider a new hose firing the parts cannon.

I understand it looks unlikely but it's low dollar and relatively easy. Normally I'd say just do the caliper, too, but I don't trust most reman stuff and OEM -- if available-- would likely be expensive.

So personally I'd start with that hose.
 
I bet bad caliper. It was extended, and rust got in. Probably pushed in ok, but seized afterwards, I swear I had that happen recently, did a pad slap, only to lose the caliper not long after.

Doubt it is the hose, but if easy and cheap to replace, why not. Just don’t let the system get empty while swapping parts out.
 
I bet bad caliper. It was extended, and rust got in. Probably pushed in ok, but seized afterwards, I swear I had that happen recently, did a pad slap, only to lose the caliper not long after.

Doubt it is the hose, but if easy and cheap to replace, why not. Just don’t let the system get empty while swapping parts out.
Yes, I don't see how a hose could hold pressure in a brake caliper unless it was obviously kinked?
I've had reasonable luck with cheapish brake calipers? I can't remember replacing one and having problems but the cars only were around for 3-4 years after. The originals all went for 10+ years and near 150k miles, so maybe they weren't prone to have problems at all.
 
I learned the hard way that the brakes on my 528e required a caliper service every couple of yrs to prevent sticking pistons. A rust belt issue. I had a stuck caliper on the SE and after I replaced the rotor and pads, my next job was to lube the slides on both cars.
 
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It’s either rust on the caliper piston or the inside of the brake caliper hose has pulled loose and is bunching up preventing the release of pressure.
 
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I had a caliper and/or hose go bad in 2 years/14k on my sons Forte. I replaced that caliper and hose and all has been well.

Side note - getting the hose off with concerns from rust so you don't mess up the metal line. @Trav suggested spray everything with your favorite penetrant, unbolting the bracket that holds the metal line and hose, THEN hold the flare nut solid and twist hose off. This way you are not fighting the rusty hose threaded connection and the rusty stuff between flare nut and metal line. 1 rust fight at a time. once hose is off you can work the flare nut metal line rust to clean it up.

https://bobistheoilguy.com/forums/threads/tried-new-penetrating-fluids.357083/post-6590773

https://bobistheoilguy.com/forums/threads/2010-forte-duralast-elite-pads-hoses-1-caliper-rotor.372431/
 
Thanks everyone-

Just to hopefully be done with this, I'll do caliper+hose on it. Will probably be Friday before I'm actually able to do this-unfortunately she's crazy busy at work(as am I). We've worked out a ferry schedule for her so that she can get where she needs to be when my FIL isn't home, as I don't feel great about her driving this or potentially cooking the new pads+rotors and making a bigger job.

If I had time to just play with it, I'd bleed it and see if that improved, but sometimes time is worth more than the money saved and I think that's where she is with it. She is looking to trade in 3-6 months, so really is just trying to keep this one(safely) drivable until then. When I needed a caliper on my MKZ a few years ago, I bought new Raybestos from Rock Auto(only place I could find non-reman) but hopefully an Autozone reman will last at least the target time frame.
 
How frequently is the brake fluid changed?
My experience--they can seize regardless of fluid changes. I used to think it would help stave off stuck calipers, but in my limited experience, nope. The rust gets into the piston anyhow. The seal is on the innermost part of the piston; the rest is supposed to be sealed by the rubber boot. But as the piston works its way out (pads wear down), the seal stays inside the bore but more of the piston is exposed. Covered by the rubber boot, but by no means hermetically sealed. It gets some rust, then pushed back in, and then it seems to finally decide to die. Not always, but I've had it happen a couple times recently, so that's my swag.

Changing fluid is still good and wise though.
 
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I learned the hard way that the brakes on my 528e required a caliper service every couple of yrs to prevent sticking pistons. A rust belt issue. I had a stuck caliper on the SE and after I replaced the rotor and pads, my next job was to lube the slides on both cars.
What does a caliper service look like?
 
Haven't done toyota brakes in ages , but on our subaru the brake pad ears get jammed in the slot where the stainless shim inserts are.

Filed, wire brushed, and cleaned rust out of the caliper keyway around that area, then I had to file then lube the ears of the new pads as they were stamped with burrs making them oversize at this critical spot. Bad design on the Subaru for sure. Also make sure you didn't over apply grease into the slid pin bores.

subaru brake pad.webp
 
aking them oversize at this critical spot. Bad design on the Subaru for sure. Also make sure you didn't over apply grease into the slid pin bores.
Had to do the same to cheapish pads. Its not a design but I think an omission of a manufacturing step. Centrics had this issue and my Akebonos did not. Little time tumbling could have solved the issue but costs I guess.
 
What does a caliper service look like?
On the 528e, I would leave the caliper attached to the hose, but loose, remove the pads and carefully press the pedal to push the piston out to where I could pull it out by hand. Then I would remove any rust on the lip. The pucks were chromed and sometimes rust pitted. I wire brushed them and feathered the pits smooth. I smeared Sil Glide on the piston and seal area then put them together. Last I would run 2 qts of DOT 4 to flush the system. The calipers on the Camry just got the slides cleaned and lubed. The SE has just over 100k and is getting close to a pad slap
 
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