For years, my 1992 Toyota Pickup, affectionately known as the “Chick Magnet,” has been my trusty project vehicle. Over the past sixteen years, I’ve enjoyed a journey of restoration and performance upgrades, from a fresh coat of paint and reupholstered interior to a rebuilt suspension and a powerful engine from LC Engineering. However, one area consistently felt like it was lagging behind the enhanced performance: the brakes. The factory brakes were adequate under normal conditions, but with the increased power, they started to pulse and feel underpowered, especially when pushed harder.
The search for a solution led me down the path of “big brake” kits. While aftermarket options with Wilwood calipers and larger rotors looked impressive, they typically required a jump to 17” wheels. I was happy with my 15” XD122 Enduro rims, which maintained a truck-like aesthetic with ample sidewall. Investing in a new set of larger wheels wasn’t something I wanted to do.
Digging deeper into online forums dedicated to Toyota Pickups, I explored what other owners had done. Many modifications were geared towards 4WD models, and mine is a 2WD. Others were focused on engine swaps, like the Chevy LS. But within the discussions, a glimmer of hope appeared: mentions of a 1-ton version of my pickup. This heavier-duty model came equipped with significantly larger calipers and rotors that seemed like they might be a direct bolt-on upgrade. Could it really be that simple? I decided to source the parts and find out.
Rockauto emerged as a budget-friendly source for 1-ton PD66 type calipers and rotors. If this turned out to be a gamble, at least it wouldn’t break the bank. Knowing that larger calipers with bigger pistons would require more fluid, I also sourced a Toyota master cylinder with a 1 and 1/16” piston, a step up from the stock 7/8” unit.
The weekend arrived, and it was time to put the puzzle pieces together. My biggest hope was that sticking with Toyota parts would mean avoiding custom fabrication of caliper brackets or drilling new mounting holes.
Image: Side-by-side comparison of the larger 1-ton brake caliper (left) with the smaller original 1/4-ton caliper (right) showcasing the size difference and cadmium plating.
The photo above clearly illustrates the difference between the 1-ton calipers and the original 1/4-ton versions. The 1-ton calipers are noticeably larger and feature a protective cadmium plating, promising long-term durability and a clean look.
First, I removed the original, smaller rotors from the hubs. Then, I carefully bolted up the larger 1-ton rotors. To my relief, everything aligned perfectly. The 1-ton rotors were a direct fit and surprisingly, weren’t even too large for the existing splash shields.
Image: Close-up view of the stock rotor and hub assembly of the 1992 Toyota Pickup, with mounting bolts removed, ready for the rotor upgrade.
The image above shows the original rotor and hub with the mounting bolts removed, prepared for the new, larger rotor.
Image: The new, larger diameter 1-ton rotor successfully bolted onto the original hub, highlighting the direct fit and size increase compared to the stock rotor.
As you can see, the 1-ton rotors bolted directly to the factory hub without any issues.
Image: A comparative shot emphasizing the slightly larger diameter of the 1-ton rotor compared to the original rotor of the 1992 Toyota Pickup, demonstrating the increased braking surface.
Here, the size difference between the 1-ton rotor and the stock rotor is evident. While it’s not a massive increase, this diameter difference translates to a significant improvement in braking leverage and heat dissipation.
The only modification needed was to the splash shields. The area where the larger caliper brackets mounted required a bit of trimming. With some tin snips and a ball-peen hammer, I carefully massaged the splash shields until the new brackets fit cleanly.
Next, the new caliper brackets were bolted into place, followed by the new brake pads and the substantial 1-ton calipers.
Image: Installation of the new caliper bracket onto the 1992 Toyota Pickup, showcasing the modified splash shield for proper fitment.
Image: The fully installed 1-ton brake caliper and pads on the 1992 Toyota Pickup, demonstrating the completed brake upgrade on one wheel.
There was one minor fabrication task involved. The flex hose brake line, which connects the hard line on the caliper to the chassis hard line, used a bracket on the original caliper to secure the connection. While a different bracket existed for the 1-ton calipers, they were discontinued by Toyota and hard to source used. To overcome this, I opted for new hard lines for the calipers, identical to the originals, and reused the cleaned-up metal brackets.
The challenge was bridging the 1.75” gap between the small caliper bracket and the mounting hole on the new, larger caliper. To solve this, I fabricated simple metal bridge pieces.
Image: Close-up of the fabricated metal bridge piece designed to extend the brake line bracket to fit the 1-ton caliper on the 1992 Toyota Pickup.
I created a square hole at one end of these bridge pieces to accommodate a smooth-headed carriage bolt. A regular bolt head would have interfered with the caliper bracket mounting bolt. To ensure a secure and vibration-resistant connection, I used a nylock nut on the carriage bolt.
Image: Detailed view of the installed caliper and the fabricated bracket bridge, illustrating how it clears the caliper bracket mounting bolt and secures the brake line.
The image above provides another view of the caliper and the fabricated bracket bridge, highlighting the clearance around the caliper bracket mounting bolt.
After ensuring all bolts were torqued to the correct specifications, the new, larger bore master cylinder was installed in place of the original unit. All the hard brake lines connected perfectly to the new master cylinder. Finally, the entire system was thoroughly bled before taking the upgraded 1992 Toyota Pickup for a test drive.
The result? Incredible. The braking performance is dramatically improved. There’s a significant increase in stopping power, and the pedal feel is noticeably better, thanks to the larger master cylinder.
The guys at the shop even joke that it’s now the first pickup truck capable of doing an “endo” – a front wheelie stop on a motorcycle. The brakes are now easier to modulate, preventing premature lock-up, yet provide immense reserve capacity and excellent pedal feedback. With the heavy-duty nature of these 1-ton brakes, I anticipate significantly extended pad life, likely exceeding 100,000 miles. This 1-ton brake upgrade is a worthwhile modification for any 1992 Toyota Pickup owner looking for enhanced safety and braking performance.
