Brake Master W/Plate Cylinder Sub-ASSY: Replacement

HINT:

See COMPONENTS 

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  REPLACEMENT  ) 
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 
   1. Slide the clip and disconnect the reservoir tube.
      Fig 1: Sliding Clip And Disconnecting Reservoir Tube

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Using SST(s), disconnect the 2 brake tubes from the brake master w/plate cylinder sub-assy.

      SST 09023-00101

      Fig 2: Disconnecting Brake Tubes From Brake Master W/Plate Cylinder Sub-Assy

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Remove the 2 nuts, then check valve bracket and the brake master w/plate cylinder assy.
      Fig 3: Removing Nuts And Checking Valve Bracket And Brake Master W/Plate Cylinder Assy

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD 
   NOTE: Make an adjustment with the brake booster assy having no vacuum. (Depress the brake pedal several times with the engine stopped.)

   HINT:

   Adjustment of the brake booster push rod is performed when the brake master cylinder sub-assy is replaced with a new one. The adjustment is not necessary when the brake master cylinder sub-assy is reinstalled and the brake booster assy is replaced with a new one.

   1. Apply the chalk to the tip of an accessory tool.

      HINT:

      An accessory tool is enclosed with new brake master cylinder sub-assy.

   2. Place the accessory tool to the brake booster assy.
   Fig 4: Placing Accessory Tool To Brake Booster Assy
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Measure the clearance between the brake booster push rod and accessory tool.

      Clearance: 0 mm (0 in.) 

      HINT:

      Adjust the clearance in following cases:

      • If there is a clearance between the accessory tool and the shell of the brake booster (floating accessory tool), the clearance is too small.
      • If the chalk does not stick on the tip of the brake booster push rod, the clearance is large.
   4. If clearance is outside of the specified range, fix the push rod using SST(s) and adjust the length of the protruding adjusting bolt.

      SST 09737-00020

      HINT:

      When adjusting the push rod, depress the brake pedal sufficiently so that the push rod sticks out.

      Fig 5: Adjusting Length Of Protruding Adjusting Bolt

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. INSTALL BRAKE MASTER W/PLATE CYLINDER SUB-ASSY 
   1. Install the brake master w/plate cylinder sub-assy and the check valve bracket with the 2 nuts.

      Torque: 13 N.m (127 kgf.cm, 9 ft.lbf) 

      Fig 6: Installing Brake Master W/Plate Cylinder Sub-Assy And Check Valve Bracket With Nuts

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Using SST(s), connect the 2 brake tubes to the brake master w/plate cylinder assy.

      SST 09023-00101

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

      Fig 7: Connecting Brake Tubes To Brake Master W/Plate Cylinder Assy

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Slide the clip and connect the reservoir tube.
      Fig 8: Sliding Clip And Connecting Reservoir Tube

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. INSTALL AIR CLEANER HOSE NO. 1 (See  REPLACEMENT  ) 
9. INSTALL AIR CLEANER ASSY (See  REPLACEMENT  ) 
10. INSTALL V-BANK COVER SUB-ASSY (See step 27 in  ADJUSTMENT  ) 
11. FILL RESERVOIR WITH BRAKE FLUID (See  BRAKE FLUID  ) 
12. BLEED MASTER CYLINDER (See  BRAKE FLUID  ) 

    SST 09023-00101

13. BLEED BRAKE LINE (See  BRAKE FLUID  ) 
14. CHECK FLUID LEVEL IN RESERVOIR (See  BRAKE FLUID  ) 
15. CHECK BRAKE FLUID LEAKAGE