Brake Booster ASSY: Replacement

DRAIN BRAKE FLUID
NOTE: Wash brake fluid off immediately if it adheres to any painted surface.
REMOVE AIR CLEANER CAP SUB-ASSY
REMOVE AIR CLEANER CASE SUB-ASSY
1. Remove the air cleaner element, then remove the 3 bolts and air cleaner case sub-assy.
REMOVE BRAKE MASTER CYLINDER SUB-ASSY (see OVERHAUL )
SST 09023-00101
SEPARATE BRAKE MASTER CYLINDER PUSH ROD CLEVIS (see REPLACEMENT )
SEPARATE CRUISE CONTROL ACTUATOR ASSY (W/ CRUISE CONTROL ACTUATOR)
1. Remove the 2 nuts and bolt from the cruise control actuator assy w/ bracket, and move the cruise control actuator assy w/ bracket aside.
Fig 1: Removing Nuts And Bolt From Cruise Control Actuator Assy W/ Bracket
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT WHEEL LH
REMOVE BRAKE BOOSTER ASSY
1. Using SST, disconnect the front brake tube No.5 and remove it.
  SST 09023-00101
2. Slide the clip, and disconnect the vacuum hose from the brake booster assy.
  
  Fig 2: Disconnecting Vacuum Hose From Brake Booster Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Separate the 2 or 3 brake tubes from the clamp, and move brake tubes aside.
  
  Fig 3: Removing Brake Tubes From Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the 4 nuts and push rod clevis.
5. Pull out the brake booster assy.
6. Remove the brake booster gasket from the brake booster assy.
7. Remove the check valve assy and grommet from the brake booster assy.
INSTALL BRAKE BOOSTER ASSY
1. Install the grommet and check valve assy.
2. Install a new brake booster gasket to the brake booster assy.
  
  Fig 4: Removing Nuts And Push Rod Clevis
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the push rod clevis and lock nut to the brake booster assy.
  HINT:
  
  After adjusting the brake pedal height, torque the lock nut.
4. Install the brake booster assy with the 4 nuts.
  Torque: 12.7 N.m (130 kgf.cm, 9 ft.lbf)
  
  Fig 5: Installing Brake Booster Assy With Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the 2 or 3 brake tubes to the clamp.
6. Connect the vacuum hose to the brake booster assy.
  
  Fig 6: Installing Brake Tubes To Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Using SST, connect the front brake tube No.5.
  SST 09023-00101
  
  Torque: 15 N.m (155 kgf.cm, 11 ft.lbf)
NOTE: Make sure that the grommet is installed correctly.

Fig 7: Connecting Front Brake Tube
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT WHEEL LH
Torque: 103 N.m (1,050 kgf.cm, 76 ft.lbf)
INSTALL CRUISE CONTROL ACTUATOR ASSY (W/CRUISE CONTROL ACTUATOR)
1. Install the cruise control actuator assy w/ bracket with 2 nuts and bolt.
  Torque: 43 N.m (438 kgf.cm, 32 ft.lbf)
Fig 8: Installing Cruise Control Actuator Assy W/ Bracket With Nuts And Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS (see REPLACEMENT )
INSTALL BRAKE MASTER CYLINDER SUB-ASSY (see OVERHAUL )
SST 09023-00101
INSTALL AIR CLEANER CASE SUB-ASSY
1. Install the air cleaner case with 3 bolts, then install the air cleaner element to the air cleaner case sub-assy.
INSTALL AIR CLEANER CAP SUB-ASSY
FILL RESERVOIR WITH BRAKE FLUID (see BRAKE FLUID )
BLEED MASTER CYLINDER (see BRAKE FLUID )
SST 09023-00101
BLEED BRAKE LINE (see BRAKE FLUID )
CHECK AND ADJUST BRAKE PEDAL HEIGHT (see BRAKE PEDAL SUB-ASSY )
CHECK PEDAL FREE PLAY (see BRAKE PEDAL SUB-ASSY )
CHECK PEDAL RESERVE DISTANCE (see BRAKE PEDAL SUB-ASSY )
CHECK FLUID LEVEL IN RESERVOIR (see BRAKE FLUID )
CHECK FOR BRAKE FLUID LEAKAGE
INSPECT BRAKE BOOSTER ASSAY (SEE BRAKE BOOSTER ASSY )