I don’t understand… does your vehicle have 40,000 miles on it or is it less than 90,000. I understand 40,000 is less than 90,000. The wording makes your inquiry a little confusing.
I’m here to tell you at 40,000 miles your brakes should not have needed replacement on your Toyota. Especially calipers! Were your brakes recently replaced with Toyota Genuine parts? Including calipers?
If you replaced your calipers then there wouldn’t be an issue with the rubbber hose being twisted or the old piston being pushed back and damaging ABS because you have to remove and replace the brake hose to the new caliper. It would be awfully hard to bolt the twisted hose into the new caliper and you wouldn’t depress the old caliper to make new pads fit because new calipers come retracted and bolted to a new bracket. Which brings me to the bracket. There are lazy techs that won’t clean the bracket and actually hammer new pads into bracket to make them fit: but you got new calipers so we can rule that out. The only other possible cause would be the aftermarket parts, especially brake pads. Often times aftermarket brake pads are slightly longer in length requiring you to grind parts of the brake pad that slide in the bracket in order to make them fit. If this is the case, then one of your brake pads is probably stuck in the bracket and constantly rubbing on the rotor.
Last possible cause would be the sliders. Toyota caliper brackets have 2 different size sliders. They both fit in each hole but only 1 of them have a rubber grommet at the end for vibration dampening purposes. If the longer slider is pushed into the short slides hole, the caliper will fit very snug and won’t allow the pad to slide through the bracket freely.
-Certified Toyota Expert