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Hydraulic Brake Booster: Disassembly

  1. Place hydraulic brake booster in vise.

    Using SST, set the hydraulic brake booster in vise.

    1. SST 09630-00014 (09631-00142), 09950-60010 (09951-00180, 09951-00190)

    Fig 1: Using SST To Mount Hydraulic Brake Booster In Vise
    G01025492Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Remove fluid level warning switch connector clamp.
    1. Disconnect the connector from the clamp.
    2. Using 5 mm socket hexagon wrench, remove the bolt and fluid level warning switch connector clamp.
      1. Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf) 
  3. Remove reservoir.
    1. Remove reservoir cap.
    2. Remove the 3 set screws and pull out the reservoir.
      1. Torque: 1.7 N.m (18 kgf.cm, 16 in.lbf) 
    3. Remove the 3 grommets.
  4. Remove cylinder boot.
    1. Loosen the lock nut, then remove the clevis and lock nut.
      1. Torque: 25 N.m (260 kgf.cm, 19 ft.lbf) 
    2. Remove the cylinder boot.
  5. Remove No. 1 and No. 2 hangers.

    Remove the 2 bolts, No. 1 and No. 2 hangers.

    1. Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf) 

  6. Remove 2 unions.

    Remove the 2 union bolts, 4 gaskets and 2 unions.

    1. Torque: 32 N.m (320 kgf.cm, 23 ft.lbf) 

  7. Remove brake actuator No. 1 tube.

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

    1. SST 09023-00100
      Fig 2: Removing Brake Actuator No. 1 Tube
      G01025493Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Torque: 15 N.m (155 kgf.cm, 11 ft.lbf) 

  8. Remove booster pump with accumulator.
    1. Remove the 2 clips and actuator hose.
    2. Remove the 4 screws and wire harness from the booster and pump.
    3. Remove the 2 bolts and No. 1 accumulator bracket.
    4. Remove the 3 cushions from the No. 1 actuator bracket.
    5. Remove the 2 bolts and No. 1 pump bracket.
    6. Remove the 2 washers, 3 cushions, 2 collars and sleeve.
    7. Remove the 2 bolts and No. 2 pump bracket.
    8. Remove the cushion from No. 2 pump bracket.
  9. Remove oil pressure sensor.
    Fig 3: Removing Oil Pressure Sensor
    G01025494Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Using 30 mm deep socket wrench, remove the oil pressure sensor.

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

  10. Remove pistons.
    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 plug and No. 1, No. 2 pistons, pulling straight out, not at an angle.
      3. Fig 4: Displaying Pistons Removal
      G01025495Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.
  11. Place booster pump in vise.

    Place the booster pump with a cloth shown in the illustration on the left.

    Fig 5: Placing Booster Pump In Vise
    G01025496Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. Remove accumulator from booster pump.
    1. Using SST, remove the accumulator.
      1. SST 09318-12010
      2. Torque: 54 N.m (550 kgf.cm, 36 ft.lbf) 
        3. Fig 6: Removing Accumulator From Booster Pump
        G01025497Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the silencer tube, spring and o-ring.
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