Hydraulic Brake Booster: Disassembly

PLACE HYDRAULIC BRAKE BOOSTER IN VISE
Using SST, set the hydraulic brake booster in vise.

SST 09630-00014 (09631-00142),

09950-60010 (09951-00180, 09951-00190)

Fig 1: Placing Hydraulic Brake Booster In Vise
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FLUID LEVEL WARNING SWITCH CONNECTOR CLAMP
1. Disconnect the connector.
2. Remove the bolt and clamp.
REMOVE RESERVOIR AND GROMMETS
1. Remove reservoir cap.
2. Remove the 3 set screws and pull out the reservoir.
  Torque: 1.7 N.m (17.5 kgf.cm, 15.2 in.lbf)
3. Remove the 3 grommets.
REMOVE CLEVIS AND CYLINDER BOOT
1. Loosen the lock nut, then remove the clevis and lock nut.
  Torque: 25 N.m (260 kgf.cm, 19 ft.lbf)
2. Remove the cylinder boot.
REMOVE BRAKE ACTUATOR TUBE NO. 1
Using SST, remove the brake actuator tube No. 1.

SST 09023-00101

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

Fig 2: Removing Brake Actuator Tube No. 1
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BOOSTER PUMP AND ASSEMBLY
1. Remove the actuator hose.
2. Remove the 4 screws and wire harness from the booster and pump.
3. Remove the 2 bolts, accumulator bracket.
4. Remove the 2 bolts and booster pump motor assembly.
5. Remove the bolt and No. 1 pump bracket.
6. Remove the 2 washers, 2 cushions, 2 collars and sleeve.
7. Remove the 2 bolts and No. 2 pump bracket.
8. Remove the cushion from No. 2 pump bracket.
ABS & BA & TRAC & VSC only: REMOVE MASTER CYLINDER PRESSURE SENSOR
Using 30 mm deeper socket wrench and remove the oil pressure sensor.

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

NOTE: If replacing the master cylinder pressure sensor, since the sensor is non-reusable, use a sensor of the supply part No shown below.

PART NO: 89637-30050

Fig 3: Removing Master Cylinder Pressure Sensor (ABS & BA & TRAC & VSC Only)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE PISTON
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 piston, pulling straight out, not at an angle.
  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.
    
    Fig 4: Pressing Piston
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE ACCUMULATOR FROM BOOSTER PUMP
1. Using SST, remove the accumulator.
  SST 09318-12010
  
  Torque: 54 N.m (550 kgf.cm, 36 ft.lbf)
2. Remove the silencer tube, spring and O-ring.
  
  Fig 5: Removing Accumulator From Booster Pump
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002