Hydraulic Brake Booster: Disassembly

REMOVE BRAKE ACTUATOR NO. 1 BRACKET
1. Using a 5 mm hexagon wrench, remove the bolt and brake actuator bracket.
  
  Fig 1: Identifying Brake Actuator Bracket No. 1 Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a screwdriver, remove the fluid level warning switch connector.
  
  Fig 2: Identifying Brake Fluid Level Warning Switch Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY
1. Using a pin punch and hammer, remove the pin from the master cylinder reservoir.
  
  Fig 3: Identifying Pin From Master Cylinder Reservoir Using Pin Punch And Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the screw and pull out the master cylinder reservoir.
  
  Fig 4: Identifying Master Cylinder Reservoir Screw
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 3 grommets from the master cylinder reservoir.
  
  Fig 5: Locating Master Cylinder Reservoir Grommets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BRAKE ACTUATOR HOSE NO.1
1. Using needle-nose pliers, slide the 2 clips and remove the brake actuator hose.
  
  Fig 6: Locating Brake Actuator Hose Clips
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BRAKE ACTUATOR NO. 1 TUBE
1. Using a union nut wrench, remove the brake actuator tube.
  
  Fig 7: Locating Brake Actuator No. 1 Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BRAKE BOOSTER WITH ACCUMULATOR PUMP ASSEMBLY
1. Using a screwdriver, remove the 2 plugs.
  
  Fig 8: Locating Plugs
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2 screws and pull the wire harness.
  
  Fig 9: Identifying Wire Harness Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a screwdriver, remove the clip.
  
  Fig 10: Identifying Clip Using Screwdriver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the brake booster with accumulator pump assembly.
5. Remove the 2 bushes and 2 collars from the brake booster with accumulator pump assembly.
6. Using a 4 mm hexagon wrench, remove the 2 pins.
  
  Fig 12: Locating Pins
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BRAKE ACTUATOR BRACKET
1. Using a 5 mm hexagon wrench, remove the bolt and brake actuator bracket.
  
  Fig 13: Identifying Brake Actuator Bracket Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BRAKE BOOSTER PUMP BRACKET
1. Using a 5 mm hexagon wrench, remove the 2 bolts and the brake booster pump bracket.
2. Remove the bush from the brake booster pump bracket.
REMOVE MASTER CYLINDER SOLENOID
1. Remove the 6 bolts and the master cylinder solenoid.
  
  Fig 15: Locating Master Cylinder Solenoid Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the gasket.
  
  Fig 16: Identifying Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE MASTER CYLINDER PUSH ROD CLEVIS
1. Loosen the lock nut on the rod operating adapter, and then remove the push rod clevis and lock nut.
  
  Fig 17: Identifying Rod Operating Adapter Lock Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Loosen the lock nut on the brake master cylinder side, and then remove the rod operating adapter and lock nut.
Fig 18: Identifying Brake Master Cylinder Lock Nut
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE MASTER CYLINDER BOOT
REMOVE PISTON
1. When pressing in the piston with a screwdriver, use a pin or the equivalent to push the C-ring from the hole in the master cylinder body. Then remove the C-ring with another screwdriver.
2. Remove the piston by pulling it straight out, not at an angle.
  NOTE: If the piston is pulled out at an angle, there is a possibility that the cylinder bore could be damaged.
  
  Fig 19: Identifying Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BRAKE BOOSTER ACCUMULATOR ASSEMBLY
1. Place the brake booster with accumulator pump assembly in a vise lined with a cloth.
2. Remove the brake booster accumulator.
3. Remove the brake booster accumulator pipe, compression spring and O-ring.