G2 Rear Disc Conversion

Discussion in 'Gen 2 Prius Accessories & Modifications' started by Justdidit, Nov 14, 2012.

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  1. Justdidit

    Justdidit LVNPZEV

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    **There revisions to the part numbers that I will EDIT once the details have been worked out.**

    Because there has been prior interest in this topic, I decided to start looking things up. Creating a shopping list for future conversion. Since the UK version Prius has 4 wheel disc brakes, this got me thinking. After comparing part numbers, this is what I came up with.

    Here are the Swappable Parts from Donor Cars
    2003-2008 Vibe
    2002-2008 Matrix
    2002–2004 Voltz
    2002-2008 Corolla
    1999-2005 Celica

    [​IMG]

    OEM Part Numbers

    Rear Rotor
    42431-47030
    additional to the other previous listed cars the 2005-2010 Scion tC rear rotors will work.
    Specs:
    Outer Dia: 269mm (10.06")
    Height: 64.6mm
    Weight: 9lbs
    Vented Rotors are optional - They are also directional so be sure to order both Right&Left
    Non-vented are swappable

    Hub & Bearing Assemblies have changed, not sure of the differences tho
    OLD 42410-02080
    OLD 42410-20190
    OLD 42410-12260
    NEW/Current 42410-01020

    Disc Brake Dust Cover & Assembly
    46503-20070 Right
    46504-20070 Left

    Caliper
    47730-20630 Right
    47750-20620 Left
    or
    47730-02110 Right
    47750-02110 Left
    Haven't figured out the Exact #s but 47730 & 47750 are correct.

    Rear Pads
    04466-20090

    1 46420-12550 cable assy, parking brake
    1 46430-12450 cable assy, parking brake
    1 46503-20070 plate sub-assy
    1 46504-20070 plate sub-assy
    4 47447-11010 pin, shoe hold
    1 47601-32030 lever sub-assy
    1 47602-32030 lever sub-assy
    4 46540-20080 shoe assy, parking
    1 90905-06044 spring, tension
    1 90905-06045 spring, tension
    1 90905-06043 spring, tension
    2 90905-06046 spring, tension
    1 47405-32010 screw set, shoe A
    1 47406-32010 screw set, shoe A
    4 47446-32010 spring, shoe hold
    2 47613-32020 strut, parking brake
    2 47715-01020 bolt, disc brake
    2 47715-01010 bolt, disc brake
    1 47730-20630 cylinder assy, di
    1 47750-20620 cylinder assy, di
    4 90240-06021 pin, w/hole
    1 04948-20010 fitting it, disc
     
    #1 Justdidit, Nov 14, 2012
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  2. Justdidit

    Justdidit LVNPZEV

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    Looks to be about $950 unless u can find cheaper donor parts at a junk yard

    Parts List:
    Bendix Ceramic Pads #8085-05016842 set $30.10
    A1 Cardone #8085-07048183 Rear Left $48.10
    A1 Cardone #8085-07001621 Rear Right $48.10
    Caliper mounting bolts – OEM, #47715-01010, (2 @ $6.10 ea.), #47715-01020, (2 @ $6.79 ea.)
    Standard Rotor Centric #8085-05116108 (2 @ $18.60)
    or
    Vented Rotor Centric StopTech Rear Left #8085-05132227 Rear Right #8085-05132228 (2 @ $68.10)
    Parts Master Wheel Hub Assembly w/ ABS #8085-07062329 (2 @ $54.10)
    Toyota OEM Dust Cover and Backing Assembly #46503-20070 and #46504-20070 (2 @ $180)
    Rear axle hub retaining bolts – M10-1.25, 35mm flange bolts, (8 @ $2.00)
    Raybestos PG Plus parking brake shoes, #796PG, $41.99
    Parking brake shoe struts – OEM, #47613-32030, (2 @ $6)
    Parking brake cables – OEM, #46420-12550 and #46430-12450, (2 @ $58)
    Techna-Fit steel-braided hose kit, #TOY-2200, $95
     
    #2 Justdidit, Nov 14, 2012
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  3. Justdidit

    Justdidit LVNPZEV

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    #3 Justdidit, Nov 14, 2012
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  4. Britprius

    Britprius Senior Member

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    Surely if using vented discs the calipers will be different as the vented discs will be thicker. Importing parts from UK wreck would be much cheaper.
     
    #4 Britprius, Nov 14, 2012
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  5. Justdidit

    Justdidit LVNPZEV

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    I'd agree but the parts are available vented rear or solid rear rotors and no-one seems to be complaining that they don't fit...

    Look at the parts available and compare part numbers:

    05 2005 Toyota Matrix Brake Rotor - Brake - Beck Arnley, Centric, EBC, Ikuta, Mountain, Pronto, Winhere, Front, Front Left, Front Right, Rear, Rear Left, Rear Right - PartsGeek

    05 2005 Toyota Corolla Brake Rotor - Brake - Beck Arnley, Centric, EBC, Ikuta, Mountain, Pronto, Winhere, Front, Front Left, Front Right, Rear, Rear Left, Rear Right - PartsGeek

    05 2005 Toyota Celica Brake Rotor - Brake - Beck Arnley, Centric, EBC, Pilenga, Pronto, Winhere, Front, Front Left, Front Right, Rear, Rear Left, Rear Right - PartsGeek

    05 2005 Pontiac Vibe Brake Rotor - Brake - Centric, EBC, Ikuta, Mountain, Pronto, Winhere, Front, Front Left, Front Right, Rear, Rear Left, Rear Right - PartsGeek
     
    #5 Justdidit, Nov 14, 2012
  6. Britprius

    Britprius Senior Member

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    The OEM rear discs are only 9mm thick or less than 3/8 inch. The caliper show in your parts diagram are for gen1 Prius. The gen2 pads are held in by the caliper itself in the same manner as the fronts.

    If different size calipers are used this is likely to lead to ABS VSC problems as the Prius uses very little braking on the rear. Disc rust is a constant problem. I can see that mechanically this is quite easy but to get a good balance front to rear could be quite challenging, to much brake spinning you out.
     
    #6 Britprius, Nov 14, 2012
  7. Justdidit

    Justdidit LVNPZEV

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    This diagram is from Asian Ver Toyota Celica:
    [​IMG]
    Drum, Brake [1]
    R42431-02100
    L42431-02100

    Rotor, Brake [2]
    R42431-20420
    L42431-20420

    Hub/Bearing Assy [3]
    w/ABS
    R42450-32041
    L42450-32041
    w/o ABS
    R42410-02080
    L42410-02080

    Rotor, ABS [4]
    NSK Brand
    R89544-47010
    L89544-47010
    Toyota Brand
    R89544-32030

    Plate, Backing Shield [7]
    R46503-20070
    L46504-20070

    Caliper [9]
    R47730-20630
    L47750-20620

    Pad Set, Brake [10]
    04466-20090

    Shoe Set, Brake [11]
    04495-47010

    Diagram of the Backing plate and parking brake assy:
    [​IMG]
    There is only one part number for the rear calipers.
     
    #7 Justdidit, Nov 14, 2012
  8. Britprius

    Britprius Senior Member

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    I will see if I can find the rear caliper part number. As I said in my previous post the gen2 pads are not held in by pins.

    I changed mine a few months back and many suppliers were trying to sell me pads like the ones you show, but checking with Toyota I found the number was different, and was then able to get the correct aftermarket pads.

    The discs are the same as the Celica. I would think the bearing hubs would not need to be changed.
     
    #8 Britprius, Nov 14, 2012
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  9. Justdidit

    Justdidit LVNPZEV

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    #9 Justdidit, Nov 14, 2012
  10. Britprius

    Britprius Senior Member

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    It's late at night hear now so will not be able to find much till tomorrow but rear hub/bearing is :- 42450-47030
     
    #10 Britprius, Nov 14, 2012
  11. Justdidit

    Justdidit LVNPZEV

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    So it looks that way...on many of the Toyota setups with rear discs...This was on a Matrix
    [​IMG]​

    [​IMG]​

    [​IMG]​

    [​IMG]​

    [​IMG]​

    [​IMG]​
     
    #11 Justdidit, Nov 14, 2012
  12. Britprius

    Britprius Senior Member

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    Imagine how rusty they get on the Prius with regen braking down to 7mph they just do not get used.
     
    #12 Britprius, Nov 14, 2012
  13. Justdidit

    Justdidit LVNPZEV

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    Thank you for that info - when I cross reference that number I also come up with:

    42450-63011
    42450-32040
    42450-32041
    42450-05040
    42450-47030
     
    #13 Justdidit, Nov 14, 2012
  14. Justdidit

    Justdidit LVNPZEV

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    Thank goodness for sunny SoCal... rarely any rust out here.
     
    #14 Justdidit, Nov 14, 2012
  15. Britprius

    Britprius Senior Member

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    I will probably be doing a tyre rotation on my Prius this weekend. I will take some pictures and post them here.
     
    #15 Britprius, Nov 14, 2012
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  16. Justdidit

    Justdidit LVNPZEV

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    From: ToyoDIY.com

    42311UBOLT, HUB (FOR REAR AXLE RH)
    90942‑02049NHW20
    42312EBOLT, HUB (FOR REAR AXLE LH)
    90942‑02049NHW20
    42421EBOLT (FOR REAR AXLE BEARING CASE RH)
    90105‑10507NHW20
    42422ABOLT (FOR REAR AXLE BEARING CASE LH)
    90105‑10507NHW20
    42431DISC, REAR
    42431‑47030NHW20
    42450AHUB & BEARING ASSY, REAR AXLE, RH
    42450‑47030NHW20
    42450BHUB & BEARING ASSY, REAR AXLE, LH
    42450‑47030NHW20
    42491PLUG, SHOE ADJUSTING HOLE (FOR PARKING BRAKE)
    47491‑22020NHW20
     
    #16 Justdidit, Nov 14, 2012
  17. Britprius

    Britprius Senior Member

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    So as I suggested the bearing hubs are the same.
     
    #17 Britprius, Nov 14, 2012
  18. Justdidit

    Justdidit LVNPZEV

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    #18 Justdidit, Nov 14, 2012
  19. Justdidit

    Justdidit LVNPZEV

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    #19 Justdidit, Nov 14, 2012
  20. Britprius

    Britprius Senior Member

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    The difference in the calipers is probably that the gen2 Prius are light weight aluminium as against cast iron. They also I believe have plastic pistons.
     
    #20 Britprius, Nov 14, 2012
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