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Hydraulic Brake Booster: Reassembly

  1. INSTALL BRAKE BOOSTER PISTON SUBASSEMBLY 
    1. Apply lithium soap base glycol grease to a new piston.
    2. Install the piston.
      NOTE: When installing, be careful not to damage the seals, etc.
    3. Install the plug.
      Fig 1: Installing Brake Booster Piston Sub-Assembly
      G04965636Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using 2 screwdrivers, install a new C-ring while pressing on the piston.

      HINT:

      Tape the screwdriver tip before use.

  2. INSTALL MASTER CYLINDER BOOT 
  3. INSTALL MASTER CYLINDER PUSH ROD CLEVIS 
    1. Install the brake master cylinder side lock nut and rod operating adapter to the brake master cylinder.

      Torque: 26 N*m (260 kgf*cm, 19 ft.*lbf) 

      Fig 2: Locating Rod Operating Adapter And Lock Nut
      G04965633Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the lock nut and master cylinder push rod clevis to the rod operating adapter.

      Torque: 26 N*m (260 kgf*cm, 19 ft.*lbf) 

      Fig 3: Locating Lock Nut
      G05638965Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL MASTER CYLINDER SOLENOID 
    1. Install a new gasket.
      NOTE: Keep all surfaces of the master cylinder solenoid, master cylinder and gasket, especially contact surfaces, away from water and dust.
      Fig 4: Identifying Gasket
      G04965631Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the master cylinder solenoid with 6 new bolts.

      Torque: 32 N*m (325 kgf*cm, 24 ft.*lbf) 

      Fig 5: Locating Master Cylinder Solenoid Bolts
      G04965630Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL BRAKE BOOSTER ACCUMULATOR PIPE 
    1. Install the brake booster accumulator pipe and compression spring.
      NOTE: Ensure that no foreign matter enters the pump.
    2. Install a new O-ring to the brake booster accumulator assembly.
    3. Install the brake booster accumulator assembly.

      Torque: 57 N*m (585 kgf*cm, 42 ft.*lbf) 

      Fig 6: Installing Brake Booster Accumulator Pipe
      G05638962Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL NO. 1 BRAKE BOOSTER PUMP BRACKET 
    1. Install the brake booster pump bush to the No. 1 brake booster pump bracket.
    2. Using a 5 mm hexagon wrench, install the No. 1 brake booster pump bracket with the 2 bolts.

      Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf) 

      Fig 7: Locating Brake Booster Pump Bracket No.2 Bolts
      G04965627Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL BRAKE BOOSTER WITH ACCUMULATOR PUMP ASSEMBLY 
    1. Using a 4 mm hexagon wrench, install the 2 pins to the brake master cylinder.

      Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf) 

    2. Install 2 new brake booster pump collars and 2 brake booster pump bushes to the brake booster with accumulator pump assembly.
      Fig 8: Locating Pins
      G04965626Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the brake booster with accumulator pump assembly to the brake master cylinder.
      Fig 9: Identifying Brake Booster With Accumulator Pump Assembly
      G05638959Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install a new clip.
      Fig 10: Identifying Clip
      G04965646Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Connect the wire harnesses with the 2 screws.

      Torque: 2.9 N*M (30 kgf*cm, 26 in.*lbf) 

      Fig 11: Locating Wire Harnesses Screws
      G04965647Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install 2 new plugs.
      Fig 12: Locating Plugs
      G04965622Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL NO. 1 BRAKE ACTUATOR TUBE 
    1. Using a union nut wrench, install the No. 1 brake actuator tube.

      Torque: without union nut wrench 

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

      With union nut wrench 

      14 N*m (145 kgf*cm, 10 ft.*lbf) 

      Fig 13: Identifying Fulcrum Length
      G05638981Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      • Use a torque wrench with a fulcrum length of 300 mm (11.8 in.).
      • The torque value for use with a union nut wrench is effective when the union nut wrench is parallel to the torque wrench.
  9. INSTALL NO. 1 BRAKE ACTUATOR HOSE 
    1. Using needle nose pliers, install the brake actuator hose with the 2 clips.
      Fig 14: Locating No. 1 Brake Actuator Hose Clips
      G05638954Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL MASTER CYLINDER RESERVOIR GROMMET 
    1. Apply lithium soap base glycol grease to 3 new reservoir grommets.
    2. Install the 3 reservoir grommets to the brake master cylinder.

      HINT:

      Be careful of the size of each grommet.

      Fig 15: Identifying Reservoir Grommets
      G04965651Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY 
    1. Install the brake master cylinder reservoir subassembly with the screw.

      Torque: 1.7 N*m (17 kgf*cm, 15 in.*lbf) 

    2. Install the master cylinder reservoir filler cap.
      Fig 16: Locating Brake Master Cylinder Reservoir Screw
      G05638952Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a pin punch and hammer, install a new pin to the brake master cylinder reservoir sub-assembly.
      Fig 17: Installing Pin To Brake Master Cylinder Reservoir Sub-Assembly
      G05638951Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL NO. 1 BRAKE ACTUATOR BRACKET 
    1. Install the brake fluid level warning switch connector to the No. 1 brake actuator bracket.
    2. Using a 5 mm hexagon wrench, install the No. 1 brake actuator bracket with the bolt.

      Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf) 

      Fig 18: Locating No. 1 Brake Actuator Bracket Bolt
      G05638949Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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