Hydraulic Brake Booster (W/VSC): Disassembly

WARNING: This page is about a different car, the 2006 Toyota Tundra and 2005 Toyota Tundra. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: As high pressure is applied to the brake actuator tube No. 1, do not deform it.

REMOVE BRAKE ACTUATOR BRACKET NO. 1
1. Using a hexagon wrench (5 mm), remove the screw and brake actuator bracket No. 1 from the hydraulic brake booster assembly.
  Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf)
  
  Fig 1: Removing Brake Actuator Bracket No. 1
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a screwdriver, remove the fluid level warning switch connector from the brake actuator bracket No. 1.
Fig 2: Removing Fluid Level Warning Switch Connector From Brake Actuator Bracket No. 1
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE MASTER CYLINDER RESERVOIR ASSEMBLY
1. Remove the screw from the master cylinder reservoir assembly.
  Torque: 1.7 N.m (17 kgf.cm, 15 in.lbf)
  
  Fig 3: Removing Master Cylinder Reservoir Assembly Screw
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a pin punch and hammer, remove the pin from the master cylinder reservoir assembly.
3. Pull out the master cylinder reservoir assembly from the hydraulic brake booster assembly.
4. Remove the 3 grommets from the master cylinder reservoir assembly.
5. Remove the cap from the master cylinder reservoir assembly.
Fig 4: Removing Pin From Master Cylinder Reservoir Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BRAKE ACTUATOR HOSE
1. Using needle nose pliers, slide the 2 clips.
2. Remove the brake actuator hose from the hydraulic brake booster assembly.
Fig 5: Removing Brake Actuator Hose
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BRAKE ACTUATOR TUBE NO. 1
1. Using SST, remove the brake actuator tube No. 1 from the hydraulic brake booster assembly.
  Torque: 15.2 N.m (155 kgf.cm, 11.2 ft.lbf)
Fig 6: Removing Brake Actuator Tube No. 1
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BRAKE BOOSTER W/ ACCUMULATOR
1. Using a screwdriver, remove the 2 plugs from the hydraulic brake booster assembly.
  
  Fig 7: Removing Plugs From Hydraulic Brake Booster Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2 screws and pull the wire harness from the hydraulic brake booster assembly.
  Torque: 2.9 N.m (30 kgf.cm, 26 in.lbf)
  
  Fig 8: Removing Wire Harness From Hydraulic Brake Booster Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a screwdriver, remove the clip from the hydraulic brake booster assembly.
  
  Fig 9: Removing Clip From Hydraulic Brake Booster Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a hexagon wrench (4 mm), loosen the 2 pins and brake booster w/ accumulator pump assembly from the hydraulic brake booster assembly.
  Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf)
5. Remove the 2 pins, 2 bushes and 2 collars from the brake booster w/ accumulator pump assembly.
Fig 10: Removing Brake Booster W/Accumulator
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BRAKE ACTUATOR BRACKET
Using a hexagon wrench (5 mm), remove the screw and brake actuator bracket from the hydraulic brake booster assembly.

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

Fig 11: Removing Brake Actuator Bracket
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BRAKE BOOSTER PUMP BRACKET
1. Using a hexagon wrench (5 mm), remove the 2 screws and brake booster pump bracket from the hydraulic brake booster assembly.
  Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf)
2. Remove the bush from the brake booster pump bracket.
Fig 12: Removing Brake Booster Pump Bracket
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE MASTER CYLINDER SOLENOID
1. Remove the 6 bolts.
  Torque: 31.9 N.m (325 kgf.cm, 24 ft.lbf)
2. Remove the master cylinder solenoid and the gasket from the master cylinder body.
NOTE: Do not let water, dust, and/or other objects attach to the surface and/or attaching surface of the master cylinder solenoid, master cylinder and body gasket.

Fig 13: Removing Master Cylinder Solenoid
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CLEVIS
1. Loosen the clevis lock nut.
  Torque: 25.5 N.m (260 kgf.cm, 19 ft.lbf)
2. Remove the clevis and clevis lock nut from the hydraulic brake booster assembly.
REMOVE PISTON
1. Pressing the piston in with a screwdriver, use a pin or equivalent to push the C-ring from the hole in the master cylinder body then remove it with another screwdriver.
2. Remove the piston, pulling it straight out, not at an angle.
NOTE:
- If pulled out at an angle, there is a possibility that the cylinder bore could be damaged.
- During reassembly, be careful not to damage the rubber lips of the piston.
Fig 15: Removing Piston
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BRAKE BOOSTER ACCUMULATOR ASSEMBLY
1. Place the brake booster w/ accumulator pump assembly in a vise between a cloth.
2. Using a socket wrench (17 mm), remove the brake booster accumulator assembly from the pump motor assembly.
  Torque: 57.4 N.m (585 kgf.cm, 42 ft.lbf)
3. Remove the brake accumulator pipe, compression spring and O-ring from the brake booster accumulator assembly and the pump motor assembly.
Fig 16: Removing Brake Booster Accumulator Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002