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Brake Booster: Removal

NOTE: Make sure to release vacuum from the brake booster before removing the master cylinder from the brake booster.
  1. REMOVE V-BANK COVER SUB-ASSEMBLY  (See REMOVAL )
  2. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH  (See REMOVAL )
  3. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH  (See REMOVAL )
  4. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY  (See REMOVAL )
  5. REMOVE WINDSHIELD WIPER MOTOR AND LINK  (See REMOVAL )
  6. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY  (See REMOVAL )
  7. REMOVE AIR CLEANER CAP SUB-ASSEMBLY  (See REMOVAL )
  8. DRAIN BRAKE FLUID 
  9. DISCONNECT NO. 1 RESERVOIR TUBE  (See REMOVAL  )
  10. DISCONNECT BRAKE LINE  (See REMOVAL  )
  11. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY  (See REMOVAL  )
  12. DISCONNECT VACUUM HOSE 
    1. Slide the clip and disconnect the vacuum hose.
  13. REMOVE BRAKE VACUUM CHECK VALVE ASSEMBLY 
    1. Remove the vacuum check valve assembly from the brake booster assembly.
  14. REMOVE CHECK VALVE GROMMET 
    1. Remove the check valve grommet from the brake booster assembly.
  15. REMOVE BRAKE PEDAL RETURN SPRING  (See REMOVAL  )
  16. SEPARATE BRAKE MASTER CYLINDER PUSH ROD CLEVIS  (See REMOVAL )
  17. REMOVE BRAKE MASTER CYLINDER PUSH ROD CLEVIS 
    1. Remove the 4 nuts and push out the brake booster assembly.
      NOTE: Do not damage the brake lines.
      Fig 1: Identifying Brake Booster Assembly Nuts
      G05417901Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Loosen the lock nut, and remove the brake master cylinder push rod clevis and lock nut from the brake booster assembly.
      Fig 2: Identifying Lock Nut & Brake Master Cylinder Push Rod Clevis
      G05417935Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. SEPARATE ENGINE WIRE 
    1. Disengage the 9 clamps.
    2. Remove the bolt and separate the engine wire from the body.
    Fig 3: Identifying Engine Wire Clamps
    G05417936Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. SEPARATE ENGINE WIRE (w/ Security Horn) 
    1. Disengage the 9 clamps, and disconnect the alarm horn connector.
    2. Remove the bolt and separate the engine wire from the body.
      3. Fig 4: Identifying Alarm Horn Connector & Engine Wire Bolt
      G05417937Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE BRAKE BOOSTER ASSEMBLY 
    1. Disengage the 2 clamps and separate the 2 brake lines from the body.
      NOTE: Be careful not to damage the brake lines or clamps. If any parts are damaged, replace them with new ones.
      Fig 5: Identifying Brake Lines & Clamps
      G05417938Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the brake booster assembly from the body.
      NOTE: Do not damage the brake lines.
  21. REMOVE BRAKE BOOSTER GASKET 
    1. Remove the brake booster gasket from the brake booster assembly.
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