Brake Master W/Plate Cylinder Sub-ASSY: Replacement

HINT:

COMPONENTS 

1. DRAIN BRAKE FLUID 
   NOTE: Wash brake fluid off immediately if it adheres to any painted surface.
2. REMOVE AIR CLEANER ASSY 
3. REMOVE BRAKE MASTER W/PLATE CYLINDER SUB-ASSY 
   1. Disconnect the level warning switch connector.
   2. Using SST, disconnect the 6 brake tubes from the brake master w/plate cylinder sub-assy.

      SST 09023-00101

      Fig 1: Disconnecting Brake Tubes From Brake Master w/Plate Cylinder Sub-Assy Using SST

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Remove the 2 nuts, and pull out the 2-way and brake master w/plate cylinder sub-assy.
      Fig 2: Pulling Out 2-Way And Brake Master w/Plate Cylinder Sub-Assy

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. 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 off.)

   HINT:

   Adjustment of the brake booster push rod is required if the brake master cylinder sub-assy is replaced with a new one. The adjustment is not necessary if 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 a new brake master cylinder sub-assy.

   2. Place the accessory tool on the brake booster assy.
   3. Measure the clearance between the brake booster push rod and accessory tool.

      Clearance: 

      0 mm (0 in.) 

      HINT:

      Adjust the clearance in the following cases:

      • If there is a clearance between the accessory tool and the shell of the brake booster (floating accessory tool), the push rod is protruding too far.
      • If the chalk does not stick on the tip of the brake booster push rod, the push rod protrusion is insufficient.
        Fig 3: Placing Accessory Tool On Brake Booster Assy

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   4. If clearance is outside the specified range, fix the push rod using SST 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 4: Fixing Push Rod Using SST

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. INSTALL BRAKE MASTER W/PLATE CYLINDER SUB-ASSY 
   1. Install the master cylinder sub-assy and 2-way with the 2 nuts.

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

      Fig 5: Installing Master Cylinder Sub-Assy And 2-Way With Nuts

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Using SST, connect the 6 brake tubes to the master cylinder sub-assy.

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

      SST 09023-00101

   3. Connect the level warning switch connector.
      Fig 6: Connecting Level Warning Switch Connector

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. FILL RESERVOIR WITH BRAKE FLUID (SEE  BLEEDING  ) 
7. BLEED MASTER CYLINDER (SEE  BLEEDING  ) 

   SST 09023-00101

8. BLEED BRAKE LINE (SEE  BLEEDING  ) 
9. INSTALL AIR CLEANER ASSY 
10. CHECK FLUID LEVEL IN RESERVOIR (SEE  BLEEDING  ) 
11. CHECK BRAKE FLUID LEAKAGE