Issues Upgrading Front Brakes to GX460

[andrewz]

I recently found out my stock front brake calipers were sticking and needing to be replaced. I saw that this is pretty common, and saw that a pretty common upgrade is to use 2010-2013 gx460 calipers, rotors and pads, they’re a direct replacement, just a little beefier. I went with the Powerstop Extreme Z36 gx460 calipers, rotors and pads. After installing, bleeding, and getting tires back on, I went to do the bedding in. I didn’t make it any farther than backing out of my garage - there was very loud clunking sounds from both front sides. I Pulled it right back in. It happens forward and reverse, clunks loudly every time it stops.

Then I watched multiple YouTube videos of this upgrade, second guessing myself to make sure I wasn’t missing anything. I did everything correctly - torqued the caliper bolts to 73 lbs, used the new pins and hardware, greased the pins, bled all 4 corners, topped off fluid, what else, that’s it about it, there really not much to it.. One of the videos even uses Powerstop brand.

I pulled the tires and made sure there’s no play or slop anywhere - there’s not, the calipers are tight, the the pads are sitting correctly, no visual issues that I could spot.

My next step troubleshooting was to take everything back off - pulled the calipers off, pulls the rotors and pads, rec-cleaned all of the connection points with a wire brush. Assembled everything back together, and still had the awful clunking sounds.

Anybody have any thoughts on this? I don’t know what else to do at this point except not use them, which is not very ideal at all.. I’ll probably contact Powerstop on Monday, but because they’re not the “correct” brakes for a gx470, I’ll think that’s where their support likely end. I’ll include a couple of pics, and a link to the parts that I used. I was going to include a video but I don’t see how to add one. Thanks in advance for info!

Pads and rotor kit:

Pardon Our Interruption

Calipers:

Pardon Our Interruption

(I Didn’t actually purchase from Summit Racing, but linked there because I had issues linking to Powerstop pages directly.)

 

[Rednexus]

They look to be set up and spaced fine. Are the caliper slide pins lubed? I'd pull them out and check them for lube if they are not.

Just FYI....I have had a pretty terrible experience with Power Stop. If you read their BBB reviews and the Google reviews for their headquarters in the Chicago area, lots of other people have had issues with them. If you can unload those brakes and get a full refund now, I'd strongly suggest it, and I'd replace them with OEM Lexus/Toyota calipers and rotors for a 2010-2013 GX460, and upgraded pads of your choice. OEM Toyota/Lexus calipers and pads are Made in Japan and surprisingly affordable.

Here is what a Power Stop braided SS hose did on my rig. While I was towing our camper. Power Stop strung me along for months on replacement hoses ("on backorder") before finally refusing to help me. They only sent me a refund after I filed a BBB complaint. I replaced all their junk SS hoses with OEM Toyota hoses.

 

[andrewz]

They look to be set up and spaced fine. Are the caliper slide pins lubed? I'd pull them out and check them for lube if they are not.

Just FYI....I have had a pretty terrible experience with Power Stop. If you read their BBB reviews and the Google reviews for their headquarters in the Chicago area, lots of other people have had issues with them. If you can unload those brakes and get a full refund now, I'd strongly suggest it, and I'd replace them with OEM Lexus/Toyota calipers and rotors for a 2010-2013 GX460, and upgraded pads of your choice. OEM Toyota/Lexus calipers and pads are Made in Japan and surprisingly affordable.

Here is what a Power Stop braided SS hose did on my rig. While I was towing our camper. Power Stop strung me along for months on replacement hoses ("on backorder") before finally refusing to help me. They only sent me a refund after I filed a BBB complaint. I replaced all their junk SS hoses with OEM Toyota hoses.
View attachment 4133688
View attachment 4133684

They look to be set up and spaced fine. Are the caliper slide pins lubed? I'd pull them out and check them for lube if they are not.

Just FYI....I have had a pretty terrible experience with Power Stop. If you read their BBB reviews and the Google reviews for their headquarters in the Chicago area, lots of other people have had issues with them. If you can unload those brakes and get a full refund now, I'd strongly suggest it, and I'd replace them with OEM Lexus/Toyota calipers and rotors for a 2010-2013 GX460, and upgraded pads of your choice. OEM Toyota/Lexus calipers and pads are Made in Japan and surprisingly affordable.

Here is what a Power Stop braided SS hose did on my rig. While I was towing our camper. Power Stop strung me along for months on replacement hoses ("on backorder") before finally refusing to help me. They only sent me a refund after I filed a BBB complaint. I replaced all their junk SS hoses with OEM Toyota hoses.
View attachment 4133688
View attachment 4133684

They look to be set up and spaced fine. Are the caliper slide pins lubed? I'd pull them out and check them for lube if they are not.

Just FYI....I have had a pretty terrible experience with Power Stop. If you read their BBB reviews and the Google reviews for their headquarters in the Chicago area, lots of other people have had issues with them. If you can unload those brakes and get a full refund now, I'd strongly suggest it, and I'd replace them with OEM Lexus/Toyota calipers and rotors for a 2010-2013 GX460, and upgraded pads of your choice. OEM Toyota/Lexus calipers and pads are Made in Japan and surprisingly affordable.

Here is what a Power Stop braided SS hose did on my rig. While I was towing our camper. Power Stop strung me along for months on replacement hoses ("on backorder") before finally refusing to help me. They only sent me a refund after I filed a BBB complaint. I replaced all their junk SS hoses with OEM Toyota hoses.
View attachment 4133688
View attachment 4133684

Yes, the slide pins are lubed. I appreciate your info regarding Powerstop quality, thanks for sharing your bad experience, that’s unfortunate you had to deal with that and makes me wish I did more research. I admittedly didn’t do as much research as I normally do before choosing to go with Powerstop, I needed to get things ordered quickly so I wouldn’t be down a vehicle too long. I might be able to return these as defective at this point, and if so just go with OEM like I usually do. Makes me second guess doing the “upgrade” gx460 vs gx470, I definitely wouldn’t be able to return OEM 460 calipers as defective if they have the same issue for some reason. Not sure what to do.

 

[Rednexus]

Yes, the slide pins are lubed. I appreciate your info regarding Powerstop quality, thanks for sharing your bad experience, that’s unfortunate you had to deal with that and makes me wish I did more research. I admittedly didn’t do as much research as I normally do before choosing to go with Powerstop, I needed to get things ordered quickly so I wouldn’t be down a vehicle too long. I might be able to return these as defective at this point, and if so just go with OEM like I usually do. Makes me second guess doing the “upgrade” gx460 vs gx470, I definitely wouldn’t be able to return OEM 460 calipers as defective if they have the same issue for some reason. Not sure what to do.

Without physically inspecting it myself, it's hard to say what might be wrong with it. The only sources of slop/knocking should be the caliper-to-steering knuckle bolts, then the caliper slide pins, then the pins used to retain the pads. If the caliper-to-steering-knuckle bolts are tight and were installed with the OEM washers, there shouldn't be a knock there. If the slide pins are the correct diameter and greased, there should not be a knock there either. After that, you are just left with the caliper retention pins - which look fine in the pictures.

I suppose it's also possible for the rotor to be the source of the issue. The GX470 rotor is centered on the wheel hub, so if that rotor has an incorrect bore (i.e., too large), it could definitely make a knocking noise. You'd need to pull the rotor off a measure the bore vs. the old one with a digital caliper.

Lastly if you want to diagnose it a bit more, put the rig up on jackstands (front and rear wheels totally off the ground), remove the front wheels, put it in gear with the engine running, and have a helper hit the brakes. Then you can hopefully visually see what is making the noise.

But, if you've already double- and triple-checked your work, then IMO you are left with bad parts. Given my experience with PS, that's not really unusual. Since you just bought these presumably you can get a refund quickly. If do you do suspect they are bad, I'd throw your GX470 brakes back on and do a 460 upgrade using OEM parts from a dealer. The chances of getting a bad part from Toyota out of the box is virtually nil (many, many times lower than a aftermarket brand).

 

[andrewz]

Yeah that’s my best guess too, that something is defective or just machined with less accurate tolerances or something, Im guessing the calipers. Since I bought the calipers and rotors/pads separate, they both came with slide pins and the pad retainer clips, so when I pulled everything off and reinstalled, I used the second set of pins and clips and still clunked. So 2 sets of those and still have issues.

At this point think I’ll just pull everything off and hopefully be able to return based on defective parts. I’ll go the OEM route for calipers for sure and figure out a good route for pads and rotors.

I’ll measure the pins, caliper bolt hole sizes and rotor bore sizes when I pull them and see if that tells me anything.

Thanks for the comments, I was racking my brain trying to figure it what could cause the clunking, there’s just not much that could be causing it..

 

[Rednexus]

Here are the part numbers I used for the GX460 upgrade on my 2007 GX470 (note that I replaced the rear rotors at the same time). OEM Japanese-made Toyota rotors are only around $70/each, which is marginally more than Chinese rotors from Rock Auto, so that's what I used front and back. I got these from a regional Toyota dealer with free shipping. The brakes work excellent and much better than my OEM 470 brakes ever did, even with the same pads.

I've had good luck with EBC Green pads but they do make quite a bit of dust. They are fairly expensive pads at around $100 per axle.

 

[Matsui]

From my own personal experience a public service announcement to all - DO NOT BUY THE POWERSTOP UPGADE KIT FOR THE GX470!!!!!!. After so much research especially on the forums, I decided to buy this kit in June 2024 from RockAuto. Fast forward to last weekend...my new mechanic who is a Brake god informed me that both my front calipers are seized and have already caused damage to the rotors and pads. He also said that the PowerStop brand is cheap quality and would never recommend.

I'm sure some people had a good experience with them but why take chances.

Now I have to redo this all over again within 2 years and planning to go with the OEM GX460 upgrade for the front.

Rednexus - thanks for the part numbers. Perfect timing.

 

[Rednexus]

Sorry to hear of your problems with PS parts, but I'm not surprised given the issues I had with them. I'm lucky their hose "only" sprung a small leak....had it leaked a bit more, or had I driven farther without noticing it (the windows were down so I smelled the brake fluid!) I might have lost all brake fluid (and brakes) while towing our camper, and might not be alive to type this reply today.

PS stuff looks nice but is only marginally better than Amazon knockoff parts, and I suspect they all made in the same Chinese factory. Their parts are not something to trust your life with, especially when OEM brake parts are relatively inexpensive.

 

[HomersCanyonero]

i was talking to AI about the benefits of the GX460 front calipers and rotors in a GX470 and I saved the interaction.

Fortunately for me, I used Toyota/lexus oem calipers and rotors. It has been working well for me.

Enjoy the read if you care to read a long post!

GX460 Brake Swap

GX460 Brake Swap on GX470 — Real Upgrade or Just Replacing Worn Parts?

Hey GXOR fam — quick reality check on the popular GX460 front brake swap for GX470s. I’ve done it myself and love the results, but let’s talk about why it feels better.

The Basics: The GX460 front rotors are larger and thicker than the GX470’s, which helps with heat dissipation — great for mountain descents or towing. But here’s the key: GX460 rotors require GX460 calipers. The GX470 calipers won’t fit over the larger rotor diameter, so this isn’t just a cosmetic swap — it’s a matched set.

The “Upgrade Feel” Myth: A lot of folks report better braking after the swap, but often that’s because they’re replacing old, sticky, or partially seized GX470 calipers with brand-new GX460 ones. That fresh pedal feel? You’d get the same result from installing new OEM GX470 calipers — it’s not magic, it’s maintenance.

What’s Actually Better:

• GX460 rotors = better thermal performance

• GX460 calipers = required to fit those rotors

• Caliper design doesn’t inherently stop better — same dual-piston setup, same pad shape, same fluid

• Replacing old calipers (of any kind) and replacing the old bulging rubber brake lines = improvement in feel

Bottom line: If your GX470 brakes feel weak, it might be age, not design. The GX460 swap is a legit upgrade for heat management, but don’t expect a night-and-day difference unless your current setup is tired.

Hope this helps someone make an informed decision. Stay safe and keep wheeling!

Short answer: Yes — GX460 front calipers are generally less prone to seizing than GX470 calipers, and the reason comes down to design changes Toyota made to fix a known issue with the earlier 120‑series calipers.

Below is a clear breakdown of what’s going on and why the GX460 design performs better.
---

Why front GX470 Calipers Seize More Often

The GX470 (and 4th‑gen 4Runner, and 120‑series Prado) use a 4‑piston fixed caliper design that is notorious for:

• Corrosion forming behind the piston seals
• Pistons sticking in their bores
• Uneven pad wear
• Dragging brakes and overheating

This is a well‑documented issue in GXOR, IH8MUD, and 4Runner forums. Toyota never issued a recall, but the problem is common enough that many GX470 owners replace calipers every 60–100k miles.

The root cause is the piston/seal design and the caliper’s susceptibility to moisture intrusion. Once rust forms behind the dust boots, the pistons no longer retract smoothly.

---

Why GX460 Calipers Are Less Likely to Seize

When Toyota moved from the GX470 (120‑series) to the GX460 (150‑series), they updated the front brake system:

Larger, thicker rotors

• The GX460 uses a thicker rotor, which requires a larger caliper body.

• This redesign also changed the piston layout and seal geometry.

Improved piston seal design

• Toyota revised the dust boot and seal arrangement to reduce moisture intrusion.

• This is the biggest factor in reducing seizure.

Better corrosion resistance

• The GX460 calipers tend to resist internal rusting better than the GX470 units.

• Many GX460 owners report 150k–200k+ miles on original calipers with no sticking.

Reduced thermal load
• The larger rotor dissipates heat better.
• Lower heat = less seal degradation = fewer stuck pistons.

Why the Upgrade Works on a GX470

The GX470 and GX460 share the same knuckle mounting points, so the GX460 caliper bolts right on. You just need:

• GX460 calipers
• GX460 rotors (thicker)
• GX470/GX460 pads (same part number)

This is why the upgrade is so popular — it’s a direct bolt‑on fix for a known weak point.

---

Bottom Line

Yes — GX460 front calipers are significantly less prone to seizing than GX470 calipers.

 

[Matsui]

Sorry to hear of your problems with PS parts, but I'm not surprised given the issues I had with them. I'm lucky their hose "only" sprung a small leak....had it leaked a bit more, or had I driven farther without noticing it (the windows were down so I smelled the brake fluid!) I might have lost all brake fluid (and brakes) while towing our camper, and might not be alive to type this reply today.

PS stuff looks nice but is only marginally better than Amazon knockoff parts, and I suspect they all made in the same Chinese factory. Their parts are not something to trust your life with, especially when OEM brake parts are relatively inexpensive.

Oh wow. I'm so glad you're OK.

Going to order the 460 calipers & rotors online from Toyota, and will order Akebono pads from somewhere - any recommendation?
Also, I replaced with the stainless steel brake lines in 2024 that have corroded. Any recommendation on what to get as a replacement? Should I stick to rubber or SS is better?

 

[HomersCanyonero]

Oh wow. I'm so glad you're OK.

Going to order the 460 calipers & rotors online from Toyota, and will order Akebono pads from somewhere - any recommendation?
Also, I replaced with the stainless steel brake lines in 2024 that have corroded. Any recommendation on what to get as a replacement? Should I stick to rubber or SS is better?

I stuck with new Toyota oem rubber lines all around. Only exception are the rear extended ss center brake lines for my long travel.

Other than that…all my brake lines and hard lines were replaced with new Toyota oem rubber and hard lines. I carry the old ones as trail spares.

 

[Rednexus]

I agree with @HomersCanyonero . OEM Toyota rubber lines should last 20+ years (and, like rotors, are inexpensive), so I'd use them everywhere except the extended lines lines for the body-to-axle in the rear, but only if you are lifted. If you are not lifted, Toyota OEM rubber lines are fine there too. I think I used MetalTech or Apache Off-Road extended body-to-axle lines on mine, but don't 100% recall and can't find the reciept.

For Akebono pads, I'd suggest getting them from somewhere reputable like Summit Racing. NAPA can also order Akenbono parts if you want to get them locally. Sometimes Japanese-made stuff is really expensive though NAPA, sometimes it's not.

 

[Matsui]

I stuck with new Toyota oem rubber lines all around. Only exception are the rear extended ss center brake lines for my long travel.

Other than that…all my brake lines and hard lines were replaced with new Toyota oem rubber and hard lines. I carry the old ones as trail spares.

Do you happen to have the part number(s) for the OEM front brake lines for GX470? I spent considerable time on Toyota parts site but not sure if I was looking at the right ones.

 

[HomersCanyonero]

My notes say this is what I bought for the front…please double check

• 460 Front Caliper RH (2010-15): 47730-60300
• 460 front Caliper LH (2010-15): 47750-60300
• DISC BRAKE ROTOR (FRONT) Part Number: 43512-60191
• Anti squeal shim 04945-60090 (1 set) $17/set
• Anti rattle fittings/springs/clips 04947-35050 $2.67
• 4731435320 Front Brake Hardline (2)
• 9094702F20 front brake rubber/flex line (2)

 

[Matsui]

My notes say this is what I bought for the front…please double check

• 460 Front Caliper RH (2010-15): 47730-60300
• 460 front Caliper LH (2010-15): 47750-60300
• DISC BRAKE ROTOR (FRONT) Part Number: 43512-60191
• Anti squeal shim 04945-60090 (1 set) $17/set
• Anti rattle fittings/springs/clips 04947-35050 $2.67
• 4731435320 Front Brake Hardline (2)
• 9094702F20 front brake rubber/flex line (2)

Perfect. I ordered the first 4 items on your list last night. For anti-squeal shim, I ordered two set as I wasn't sure if 1 set covers both sides.

I'll order the last 3 items as well.

Super helpful. Thanks!

 

[Rednexus]

Here are the front and rear hoses that I ordered several years ago. The rear brake hoses are side-specific. This was before the era of high tariffs and the end to the de minimis exemption, so OEM parts could be had cheaply from Partsouq in the UAE. Now I just get them though regional dealers.

 

[HomersCanyonero]

Here are the front and rear hoses that I ordered several years ago. The rear brake hoses are side-specific. This was before the era of high tariffs and the end to the de minimis exemption, so OEM parts could be had cheaply from Partsouq in the UAE. Now I just get them though regional dealers.
View attachment 4135255

Yeah, luckily I finished 98% of my build before tariffs and high inflation. Now I just got to watch out for repairs and maintenance!

 

[iwashmycar]

I did not read all the posts because I am lazy sometimes......BUT could those Powerstop calipers be for the newer GX460? They use the larger 14mm mounting bolts compared to the 12mm ones you need. (like what the 10-15 Calipers linked above will have) With torqued bolts I dont think it should necessarily clunk but you never know.

 

[mmm635]

Yeah that’s my best guess too, that something is defective or just machined with less accurate tolerances or something, Im guessing the calipers. Since I bought the calipers and rotors/pads separate, they both came with slide pins and the pad retainer clips, so when I pulled everything off and reinstalled, I used the second set of pins and clips and still clunked. So 2 sets of those and still have issues.

At this point think I’ll just pull everything off and hopefully be able to return based on defective parts. I’ll go the OEM route for calipers for sure and figure out a good route for pads and rotors.

I’ll measure the pins, caliper bolt hole sizes and rotor bore sizes when I pull them and see if that tells me anything.

Thanks for the comments, I was racking my brain trying to figure it what could cause the clunking, there’s just not much that could be causing it..

Not sure how you bled your brakes, but that is where you might want to revisit in an attempt to get rid of that clunking. In your pic the lower, inner piston is further out than your upper piston which usually indicates uneven pressure on the pad, hence noise and clunking. The inner pad does not look completely vertical in the normal resting position like the outer, which might mean the lower piston is not retracting properly.

Try bleeding your brakes again and see if that helps. Opening a brake system usually requires more than one bleed - not in one sitting. If it does not, then remove the calipers and insert a piece of wood in between the pistons and cycle the brakes to allow the pistons to run their full travel - in the case of being stuck. Compress them and do it a few more times.

 

[andrewz]

Just to update - I took the Powerstops off and put my old stuff back on temporarily until I buy OEMs. I’m in the process of returning the Powerstops. I didn’t end up comparing with digital calipers though, but nothing noticeable visually.

Thanks for the oem part numbers, that’s helpful! Correct me if I’m wrong, but the anti-squeal shim set is only needed if I go with the oem pads, right?

I did not read all the posts because I am lazy sometimes......BUT could those Powerstop calipers be for the newer GX460? They use the larger 14mm mounting bolts compared to the 12mm ones you need. (like what the 10-15 Calipers linked above will have) With torqued bolts I dont think it should necessarily clunk but you never know.

The caliper set I bought was for the earlier gx460s.14mm bolts wouldn’t have fit in the holes, good thought though.

Not sure how you bled your brakes, but that is where you might want to revisit in an attempt to get rid of that clunking. In your pic the lower, inner piston is further out than your upper piston which usually indicates uneven pressure on the pad, hence noise and clunking. The inner pad does not look completely vertical in the normal resting position like the outer, which might mean the lower piston is not retracting properly.

Try bleeding your brakes again and see if that helps. Opening a brake system usually requires more than one bleed - not in one sitting. If it does not, then remove the calipers and insert a piece of wood in between the pistons and cycle the brakes to allow the pistons to run their full travel - in the case of being stuck. Compress them and do it a few more times.

Good eye noticing that the pads are not completely vertical in the pic, but they’re just not pulled apart at the bottom at the point, the pic was right after I put them in but had not bled yet. I did bleed thoroughly twice, maybe I should have done a 3rd too I guess, but I appreciate the input.

Sounds like bad experiences with Powerstop all around. Thanks for all the comments!