Brake Master Cylinder Sub-ASSY: Overhaul

1. Disconnect the brake fluid level switch connector from the reservoir sub-assy.
2. M/T:

   Slide the clip, and disconnect the clutch reservoir tube No. 1 from the reservoir sub-assy.

3. Using SST, disconnect the 2 brake tubes from the master cylinder sub-assy.

   SST 09023-00101

   Fig 1: Disconnecting Brake Tubes From Master Cylinder Sub-Assy

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using SST, disconnect the2 or 3 brake tubes from the No. 1 way.

   SST 09023-00101

   Fig 2: Disconnecting Brake Tubes From No. 1 Way

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Remove the 2 nuts, and pull out the master cylinder sub-assy, No.1 way and check valve bracket.

Fig 3: Pulling Out Master Cylinder Sub-Assy

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the stopper screw and reservoir sub-assy.
2. Remove the cap and strainer from the reservoir sub-assy.
3. Remove the 2 grommets from the master cylinder sub-assy.

1. Hold the master cylinder sub-assy in a vise with the 2 aluminum plates in between.
2. Remove the O-ring from the master cylinder sub-assy.
3. Push in the piston and remove the snap ring using snap ring pliers.
   NOTE: When pushing in the piston, the fluid left in the cylinder may spatter.
   Fig 4: Removing O-Ring From Master Cylinder Sub-Assy

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. w/o VSC:

   Push in the piston and remove the piston stopper bolt and gasket.

   Fig 5: Removing Piston Stopper Bolt And Gasket

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. w/ VSC:

   Push in the piston and remove the straight pin by turning over the cylinder body.

   NOTE: Use a shop rag to prevent from damaging.
6. Remove the No.1 piston from the master cylinder body by pulling it straight out.
   NOTE: Do not scratch the inside of the cylinder body.
   Fig 6: Removing No.1 Piston From Master Cylinder Body

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Tap the flanged part against wooden blocks until the end of the No.2 piston comes out. When the end of the No.2 piston comes out, pull out the No.2 piston straight from the master cylinder body.
   NOTE: Do not scratch the inside of the cylinder body.

Fig 7: Taping Flanged Part Against Wooden Blocks

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Check the inside of the brake master cylinder for scratch.

HINT:

Replace the master cylinder sub-assy if necessary.

1. Placing aluminum plates between the vise and the master cylinder sub-assy, place the master cylinder sub-assy in the vise.
2. Apply lithium soap base glycol grease to the rubber part as shown in the illustration.
3. Install the No.1 and No.2 pistons to the master cylinder body.
   Fig 8: Applying Lithium Soap Base Glycol Grease To Rubber Part

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   • Install the piston straight carefully not to give any damage to the inside of the cylinder.
   • Do not damage the lip of the cylinder cup.
   • w/ VSC:

     Install the No.2 piston with the pin hole facing upward.

4. w/o VSC:

   Push in the piston and install a new gasket and a new piston stopper bolt.

   Torque: 10 N.m (102 kgf.cm, 7 ft.lbf) 

   Fig 9: Installing Gasket And Piston Stopper Bolt - w/o VSC

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. w/ VSC:

   Install the straight pin with the piston pushed in.

   NOTE: Make sure that the straight pin is installed correctly.
   Fig 10: Installing Gasket And Piston Stopper Bolt - with VSC

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Install the hole snap ring using snap ring pliers with the piston pushed in.
   NOTE: Do not scratch the inside of the cylinder body.
7. Apply lithium soap base glycol grease to a new O-ring.
8. Install the O-ring to the master cylinder body.

Fig 11: Installing Hole Snap Ring Using Snap Ring Pliers

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the strainer and cap to the reservoir sub-assy.
2. Apply lithium soap base glycol grease to the 2 grommets and install them to the master cylinder body.
3. Install the reservoir sub-assy with the stopper screw.

1. Set SST on the master cylinder and lower the rod of the SST until it slightly touches the piston.

   SST 09737-00013

2. Apply chalk to the flat tip of the SST rod. Turn the SST upside down and measure the clearance between the brake booster push rod and the SST.

   Clearance: -0.21 to 0 mm (-0.0083 to 0 in.) 

   HINT:

   If there is a clearance between the SST main body and the shell of the brake booster, 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 12: Applying Chalk To Flat Tip Of SST Rod

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. If the clearance is not within the standard, adjust the length by holding the rod using SST and turning the tip of the rod using a socket driver (7 mm).

   SST 09737-00020

   HINT:

   Check the push rod clearance again after adjustment.

Fig 13: Adjusting Length By Holding Rod Using SST

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the master cylinder sub-assy, No.1 way and check valve bracket with the 2 nuts.

   Torque: 12.5 N.m (127 kgf.cm, 9 ft.lbf) 

   Fig 14: Installing Master Cylinder Sub-Assy, No.1 Way

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, connect the 2 or 3 brake tubes to the No.1 way.

   SST 09023-00101

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

   Fig 15: Connecting 2 Or 3 Brake Tubes To No.1 Way

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

   SST 09023-00101

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

4. M/T:

   Connect the clutch reservoir tube No.1 with the clip to master cylinder reservoir sub-assy.

5. Connect the brake fluid level switch connector to master cylinder reservoir sub-assy.

Fig 16: Connecting Brake Fluid Level Switch Connector To Master Cylinder Reservoir Sub-Assy

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SST 09023-00101