Hydraulic Brake Booster: Disassembly

REMOVE NO. 1 BRAKE ACTUATOR BRACKET
1. Using a 5 mm hexagon wrench, remove the bolt and No. 1 brake actuator bracket.
  
  Fig 1: Locating No. 1 Brake Actuator Bracket Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a screwdriver, disconnect the brake fluid level warning switch connector from the No. 1 brake actuator bracket.
  
  Fig 2: Disconnecting Brake Fluid Level Warning Switch Connector From No. 1 Brake Actuator Bracket
  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 brake master cylinder reservoir subassembly.
  
  Fig 3: Removing Pin From Brake Master Cylinder Reservoir Subassembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the screw and pull out the brake master cylinder reservoir sub-assembly.
3. Remove the master cylinder reservoir filler cap.
  
  Fig 4: Locating Brake Master Cylinder Reservoir Screw
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE MASTER CYLINDER RESERVOIR GROMMET
1. Remove the 3 reservoir grommets from the master cylinder reservoir sub-assembly.
  
  Fig 5: Locating Reservoir Grommets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 BRAKE ACTUATOR HOSE
1. Using needle nose pliers, slide the 2 clips and remove the brake actuator hose and 2 clips.
  
  Fig 6: Locating No. 1 Brake Actuator Hose Clips
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 BRAKE ACTUATOR TUBE
1. Using a union nut wrench, remove the No. 1 brake actuator tube.
  
  Fig 7: Removing No. 1 Brake Actuator 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 disconnect the wire harnesses from the master cylinder solenoid.
  
  Fig 9: Locating Wire Harnesses Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a screwdriver, remove the clip.
  
  Fig 10: Removing Clip
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the brake booster with accumulator pump assembly from the brake master cylinder.
5. Remove the 2 brake booster pump collars and 2 brake booster pump bushes from the brake booster with accumulator pump assembly.
  
  Fig 11: Identifying Brake Booster With Accumulator Pump Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Using a 4 mm hexagon wrench, remove the 2 pins.
  
  Fig 12: Locating Pins
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 BRAKE BOOSTER PUMP BRACKET
1. Using a 5 mm hexagon wrench, remove the 2 bolts and No. 1 brake booster pump bracket from the brake master cylinder solenoid.
2. Remove the brake booster pump bush from the No. 1 brake booster pump bracket.
  
  Fig 13: Locating Brake Booster Pump Bracket No.2 Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BRAKE BOOSTER ACCUMULATOR PIPE
1. Secure the brake booster with accumulator pump assembly in a vise.
2. Remove the brake booster accumulator assembly.
3. Remove the O-ring from the brake booster accumulator assembly.
  NOTE: Ensure no foreign matter enters the pump.
4. Remove the brake booster accumulator pipe and compression spring.
  
  Fig 14: Securing Brake Booster With Accumulator Pump Assembly In Vise
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE MASTER CYLINDER SOLENOID
1. Remove the 6 bolts and 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 remove the push rod clevis and lock nut.
  
  Fig 17: Locating Lock Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Loosen the lock nut on the brake master cylinder side, and remove the rod operating adapter and lock nut.
REMOVE MASTER CYLINDER BOOT

Fig 18: Locating Rod Operating Adapter And Lock Nut
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BRAKE BOOSTER PISTON SUBASSEMBLY
1. Pressing the piston in with a screwdriver, insert a pin or equivalent from the hole in the master cylinder body to hold the C-ring, and then remove it with another screwdriver.
  HINT:
  
  Tape the screwdriver tip before use.
  
  Fig 19: Removing Brake Booster Piston Subassembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the plug from the piston.
3. 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.