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Disassembly (GS 300 & GS 430)

WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2002 Lexus SC 430, 2002 Lexus RX 300, 2002 Lexus LX 470, 2002 Lexus LS 430, and 2002 Lexus IS 300. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove hydraulic brake booster. See HYDRAULIC BRAKE BOOSTER  under REMOVAL & INSTALLATION.
  2. Using special tool (09630-00014), 09631-00142), (09950-60010), (09951-00180) and (09951-00190), place brake booster in vise. See Fig 1.
  3. Remove reservoir cap. Remove 3 set screws, and pull out reservoir. Remove 3 grommets. Loosen lock nut, remove clevis and lock nut, and remove caliper boot.
  4. Using a 30 mm deep socket wrench, remove oil pressure sensor. See Fig 2.
  5. Press piston in with screwdriver and use a pin to push snap ring from hole in body, then remove.
  6. Remove piston, pulling STRAIGHT out. Disconnect actuator hose. Remove 2 bolts, hanger and clamp.
  7. Using special tool (09023-00100), remove brake actuator tube No. 1. See Fig 3.
  8. Remove screws and wire harness.
  9. Using 5 mm socket hexagon wrench, remove bolts, No. 1 and No. 2 accumulator brackets, booster pump and accumulator with No. 1 pump bracket. Remove bolt and No. 1 pump bracket. Remove washers, cushions, collars and sleeve. Remove bolts and No. 2 pump bracket and cushion.
  10. Place cloth around booster and place booster pump in vise. Using special tool (09318-12010), remove accumulator. Remove silencer tube. Remove spring and "O" ring. Ensure no foreign matter enters pump.
    11. CAUTION: Never cut at a stretch. When outer body of accumulator is cut, gas discharges. Be careful of flying debris.
  11. To dispose of accumulator, drain high pressure gas from accumulator. Place accumulator in a vise. Cover accumulator and a saw with a cloth. Cut accumulator body slowly to release gas.
Fig 1: Placing Hydraulic Brake Booster In Vise (GS 300 & GS 430 Shown, LX 470 & SC 430 Similar)
G00185229Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 2: Exploded View Of Hydraulic Brake Booster Components
G00185230Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 3: Removing Brake Actuator No. 1 Tube
G00185231Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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