Hydraulic Brake Booster: Disassembly

Using SST, set the hydraulic brake booster in vise.

SST 09630-00014 (09631-00142), 950-60010 (09951-00180, 09951-00190)

Fig 1: Setting Hydraulic Brake Booster In Vise

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the reservoir cap.
2. Remove the 3 set screws and pull out the reservoir.

   Torque: 1.7 N.m (17.5 kgf.cm, 15.2 in.lbf) 

3. Remove the 3 grommets.

Loosen the lock nut, then remove the clevis and lock nut.

Torque: 25 N.m (260 kgf.cm, 19 ft.lbf) 

Using 30 mm deeper socket wrench and remove the oil pressure sensor.

Torque: 81 N.m (830 kgf.cm, 60 ft.lbf) 

Fig 2: Removing Oil Pressure Sensor

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Pressing the piston in with a screwdriver, use a pin or an equivalent to push the snap ring from the hole in the body then remove it with another screwdriver.
2. Remove the piston, pulling straight out, not at an angle.
   NOTE:

   • If pulled out and installed at an angle, there is a possibility that the cylinder bore could be damaged.
   • At the time of reassembly, be careful not to damage the rubber lips on the pistons.
   Fig 3: Pressing Piston With Use Pin Or Equivalent Push Snap Ring From Hole

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using SST, remove the brake actuator No. 1 tube.

SST 09023-00101

Torque: 15 N.m (155 kgf.cm, 11 ft.lbf) 

Fig 4: Removing Brake Actuator No. 1 Tube

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 4 screws and wire harness.

   HINT:

   At the time of installation, please refer to the following item. Replace the used wire harness with new one.

2. Using 5 mm socket hexagon wrench, remove the 3 bolts, No. 1 accumulator bracket, No. 2 accumulator bracket, booster pump and accumulator with the No. 1 pump bracket.
3. Remove the bolt and No. 1 pump bracket, and remove the washers, 2 cushions, 2 collars and sleeve.
4. Remove the 2 bolts, No. 2 pump bracket and cushion.

Place the booster pump with a cloth shown in illustration.

Fig 5: Placing Booster Pump In Vise With Cloth

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1. Using SST, remove the accumulator.

   SST 09318-12010

   Torque: 54 N.m (550 kgf.cm, 36 ft.lbf) 

2. Remove the silencer tube, spring and O-ring.
   NOTE: Ensure no foreign matter enters the pump.
   Fig 6: Using SST Remove Accumulator

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002