Brake Booster ASSY: Replacement

HINT:

COMPONENTS: See AIR CONDITIONING RADIATOR ASSY

1. DRAIN BRAKE FLUID 
   NOTE: Wash the brake fluid off immediately if it adheres to any painted surfaces.
2. REMOVE V-BANK COVER SUB-ASSY (See step 10 in  ADJUSTMENT  ) 
3. REMOVE AIR CLEANER ASSY (See  REPLACEMENT  ) 
4. REMOVE AIR CLEANER HOSE NO. 1 (See  REPLACEMENT  ) 
5. REMOVE BRAKE MASTER W/PLATE CYLINDER SUB-ASSY (See  BRAKE MASTER W/PLATE CYLINDER SUB-ASSY  ) 

   SST 09023-00101, 09737-00012

6. REMOVE FR WIPER ARM LH (See  OVERHAUL  ) 
7. REMOVE FR WIPER ARM RH (See  OVERHAUL  ) 
8. REMOVE FRONT FENDER TO COWL SIDE SEAL RH (See  OVERHAUL  ) 
9. REMOVE FRONT FENDER TO COWL SIDE SEAL LH (See  OVERHAUL  ) 
10. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSY (See  OVERHAUL  ) 
11. REMOVE WINDSHIELD WIPER MOTOR & LINK ASSY (See step 6  WIPER & WASHER  ) 
12. REMOVE FRONT SHOCK ABSORBER CAP RH (W/AIR SUSPENSION) (See  PNEUMATIC FRONT LH W/SHOCK ABSORBER CYLINDER ASSY  ) 
13. REMOVE FRONT SHOCK ABSORBER CAP LH (W/AIR SUSPENSION) (See  PNEUMATIC FRONT LH W/SHOCK ABSORBER CYLINDER ASSY  ) 
14. REMOVE COWL TOP PANEL SUB-ASSY OUTER (See  OVERHAUL  ) 
15. REMOVE BRAKE PEDAL RETURN SPRING 
    1. Remove the brake pedal return spring.
16. REMOVE BRAKE MASTER CYLINDER PUSH ROD CLEVIS 
    1. Remove the clip and the push rod pin.
    2. Loosen the push rod lock nut and remove the push rod clevis.
    Fig 1: Removing Brake Master Cylinder Push Rod Clevis
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
17. SEPARATE WIRE HARNESS 
    1. Pull out the grommet of the wire harness from the body.
    2. Release the clip fitting of the wire harness.
    3. Remove the bolt and separate the wire harness from the body.
    Fig 2: Removing Wire Harness
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
18. SEPARATE BRAKE TUBE 
    1. Release the 2 claw fittings of the clamp and separate the 2 brake tubes from the body.
       NOTE: Be careful not to damage the brake tubes.
       Fig 3: Separating Brake Tube

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
19. REMOVE BRAKE BOOSTER ASSY 
    1. Slide the clip and disconnect the vacuum hose from the check valve assy.
       Fig 4: Sliding Clip And Disconnecting Vacuum Hose From Check Valve Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 4 nuts and pull out the brake booster assy.
       NOTE: Be careful not to damage the brake tubes and the wire harness.
       Fig 5: Removing Nuts And Pulling Out Brake Booster Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
20. REMOVE BRAKE BOOSTER GASKET 
    1. Remove the brake booster gasket from the brake booster assy.
21. REMOVE BRAKE VACUUM CHECK VALVE ASSY 
    1. Remove the check valve assy and the grommet from the brake booster assy.
22. INSTALL BRAKE VACUUM CHECK VALVE ASSY 
    1. Install the grommet and the check valve assy to the brake booster assy.
       Fig 6: Installing Grommet And Check Valve Assy To Brake Booster Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
23. INSTALL BRAKE BOOSTER GASKET 
    1. Install a new brake booster gasket to the brake booster assy.
24. INSTALL BRAKE BOOSTER ASSY 
    1. Install the brake booster assy with the 4 nuts.

       Torque: 13 N.m (130 kgf.cm, 9 ft.lbf) 

       NOTE: Be careful not to damage the brake tubes and the wire harness.
       Fig 7: Installing Brake Booster Assy With Nuts

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the vacuum hose to the brake booster assy and slide the clip
       Fig 8: Connecting Vacuum Hose To Brake Booster Assy And Slide Clip

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
25. INSTALL BRAKE TUBE 
    1. Install the 2 clamps of the brake tube to the body.
       NOTE: Be careful not to damage the brake tubes.
       Fig 9: Installing Clamps Of Brake Tube To Body

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
26. INSTALL WIRE HARNESS 
    1. Install the clip of the wire harness to the body.
    2. Install the grommet of the wire harness to the body.
    3. Install the bolt.
    Fig 10: Installing Wire Harness
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
27. INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS 
    1. Install the push rod clevis and the push rod lock nut.

       Torque: 26 N.m (265 kgf.cm, 19 ft.lbf) 

       HINT:

       After adjusting the brake pedal height, torque the lock nut.

    2. Apply lithium soap base glycol grease to the clevis pin.
    3. Install the push rod pin and the clip.
    Fig 11: Installing Brake Master Cylinder Push Rod Clevis
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
28. INSTALL BRAKE PEDAL RETURN SPRING 
    1. Install the brake pedal return spring.
29. INSTALL COWL TOP PANEL SUB-ASSY OUTER (See step 63 in  OVERHAUL  ) 
30. INSTALL FRONT SHOCK ABSORBER CAP RH (W/AIR SUSPENSION) (See  PNEUMATIC FRONT LH W/SHOCK ABSORBER CYLINDER ASSY  ) 
31. INSTALL FRONT SHOCK ABSORBER CAP LH (W/AIR SUSPENSION) (See  PNEUMATIC FRONT LH W/SHOCK ABSORBER CYLINDER ASSY  ) 
32. INSTALL WINDSHIELD WIPER MOTOR & LINK ASSY (See step 9 in  REPLACEMENT  ) 
33. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSY 
34. INSTALL FRONT FENDER TO COWL SIDE SEAL LH 
35. INSTALL FRONT FENDER TO COWL SIDE SEAL RH 
36. INSTALL FR WIPER ARM LH (See  WIPER & WASHER  ) 
37. INSTALL FR WIPER ARM RH (See  WIPER & WASHER  ) 
38. INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD (See  BRAKE MASTER W/PLATE CYLINDER SUB-ASSY  ) 

    SST 09737-00020

39. INSTALL BRAKE MASTER W/PLATE CYLINDER SUB-ASSY (See  BRAKE MASTER W/PLATE CYLINDER SUB-ASSY  ) 

    SST 09023-00101

40. INSTALL AIR CLEANER HOSE NO. 1 (See  REPLACEMENT  ) 
41. INSTALL AIR CLEANER ASSY (See  REPLACEMENT  ) 
42. INSTALL V-BANK COVER SUB-ASSY (See step 27 in  ADJUSTMENT  ) 
43. FILL RESERVOIR WITH BRAKE FLUID (See  BRAKE FLUID  ) 
44. BLEED MASTER CYLINDER (See  BRAKE FLUID  ) 

    SST 09023-00101

45. BLEED BRAKE LINE (See  BRAKE FLUID  ) 
46. CHECK FLUID LEVEL IN RESERVOIR (See  BRAKE FLUID  ) 
47. CHECK BRAKE FLUID LEAKAGE 
48. CHECK AND ADJUST BRAKE PEDAL HEIGHT (See  BRAKE PEDAL SUB-ASSY  )