Brake Booster ASSY: Replacement

HINT:

See COMPONENTS 

1. DRAIN BRAKE FLUID 
   NOTE: Wash off the brake fluid immediately if it comes into contact with a painted surface.
2. REMOVE AIR CLEANER ASSY 
3. REMOVE BRAKE MASTER CYLINDER SUB-ASSY (See  BRAKE MASTER CYLINDER SUB-ASSY  ) 

   SST 09023-00101

4. DISCONNECT VACUUM HOSE ASSY 
   1. Remove the bolt and separate the vacuum hose from the vacuum hose bracket.
   2. Slide the clip and disconnect the vacuum hose from the brake booster.
   Fig 1: Disconnecting Vacuum Hose Assy

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. REMOVE FRONT DOOR SCUFF PLATE LH (See step 12 on  REPLACEMENT  ) 
6. REMOVE COWL SIDE TRIM SUB-ASSY LH (See step 15 on  REPLACEMENT  ) 
7. REMOVE INSTRUMENT PANEL SUB-ASSY UPPER (See step 18 on  REPLACEMENT  ) 
8. REMOVE PUSH ROD PIN 
   1. Remove the clip and push rod pin.
9. REMOVE BRAKE MASTER CYLINDER PUSH ROD CLEVIS 
   1. Loosen the lock nut and remove the push rod clevis.
10. REMOVE FRONT BRAKE TUBE NO. 5 
    1. Using SST and remove the front brake tube No. 5.

    SST 09023-00101

    Fig 2: Removing Front Brake Tube No. 5

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. REMOVE BRAKE BOOSTER ASSY 
    1. Remove the 4 nuts.
    2. Pull out the brake booster assy.
    Fig 3: Removing Brake Booster Assy

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. REMOVE BRAKE BOOSTER GASKET 
13. INSTALL BRAKE BOOSTER GASKET 
    1. Install a new brake booster gasket to the brake booster.
14. INSTALL BRAKE BOOSTER ASSY 
    1. Install the brake booster with the 4 nuts.

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

    Fig 4: Installing Brake Booster Assy

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
15. INSTALL FRONT BRAKE TUBE NO. 5 
    1. Using SST install the front brake tube No. 5.

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

    SST 09023-00101

    Fig 5: Installing Front Brake Tube No. 5

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
16. INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS 
    1. Install the push rod clevis and lock nut.
17. INSTALL PUSH ROD PIN 
    1. Install the push rod pin and clip.

    HINT:

    Apply the lithium soap base glycol grease to the part indicated by arrow (See COMPONENTS ).

18. INSTALL INSTRUMENT PANEL SUB-ASSY UPPER (See step 60 on  OVERHAUL  ) 
19. INSTALL COWL SIDE TRIM SUB-ASSY LH (See step 62 on  OVERHAUL  ) 
20. INSTALL FRONT DOOR SCUFF PLATE LH (See step 63 on  OVERHAUL  ) 
21. INSTALL VACUUM HOSE ASSY 
    1. Install the vacuum hose and vacuum hose bracket to the body with a bolt.

       Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) 

    2. Connect the vacuum hose to the brake booster with the clip.
    Fig 6: Installing Vacuum Hose Assy

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
22. INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD 

    SST 09737-00013, 09737-00020

23. REMOVE BRAKE MASTER CYLINDER SUB-ASSY (See  BRAKE MASTER CYLINDER SUB-ASSY  ) 

    SST 09023-00101

24. INSTALL AIR CLEANER ASSY 
25. FILL RESERVOIR WITH BRAKE FLUID 
26. BLEED MASTER CYLINDER (See  BLEEDING  ) 

    SST 09023-00101

27. BLEED BRAKE LINE (See  BLEEDING  ) 
28. CHECK FLUID LEVEL IN RESERVOIR 
29. CHECK BRAKE FLUID LEAKAGE 
30. CHECK AND ADJUST BRAKE PEDAL HEIGHT (See  ADJUSTMENT   or  ADJUSTMENT  )