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Disassembly [08/2015 - ]: Procedure

  1. REMOVE NO. 1 BRAKE ACTUATOR BRACKET 
    1. Using a 5 mm hexagon wrench, remove the bolt and No. 1 brake actuator bracket.
      GTY247706Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, remove the brake fluid level warning switch connector from the No. 1 brake actuator bracket.
      GTY154933Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY 
    1. Using a pin punch and hammer, remove the pin from the brake master cylinder reservoir.
      GTY732167Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Pin Punch
    2. Remove the screw and pull out the brake master cylinder reservoir sub-assembly.
      GTY244507Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the master cylinder reservoir filler cap.
  3. REMOVE MASTER CYLINDER RESERVOIR GROMMET 
    1. Remove the 3 reservoir grommets from the master cylinder reservoir.
      GTY671061Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE NO. 1 BRAKE ACTUATOR HOSE 
    1. Using needle nose pliers, slide the 2 clips and remove the brake actuator hose and 2 clips.
      GTY671060Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE NO. 1 BRAKE ACTUATOR TUBE 
    1. Using a union nut wrench, remove the No. 1 brake actuator tube.
      GTY212068Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE BRAKE BOOSTER WITH ACCUMULATOR PUMP ASSEMBLY 
    1. Using a screwdriver, remove the 2 plugs.
      GTY610379Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 screws and disconnect the wire harnesses from the master cylinder solenoid.
      GTY596071Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a screwdriver, remove the clip.
      GTY141994Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the brake booster with accumulator pump assembly from the brake master cylinder.
      GTY642764Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the 2 brake booster pump collars and 2 brake booster pump bushes from the brake booster with accumulator pump assembly.
    6. Using a 4 mm hexagon wrench, remove the 2 pins.
      GTY610382Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. 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.
      GTY596069Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the brake booster pump bush from the No. 1 brake booster pump bracket.
  8. REMOVE NO. 3 BRAKE ACTUATOR BRACKET 
    1. Remove the bolt and No. 3 brake actuator bracket from the brake master cylinder.
      GTY216276Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE BRAKE BOOSTER ACCUMULATOR PIPE 
    1. Secure the brake booster with accumulator pump assembly in a vise.
      GTY231324Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the brake booster accumulator.
    3. Remove the O-ring from the brake booster accumulator.
      NOTE:

      Make sure no foreign matter enters the pump.

    4. Remove the brake booster accumulator pipe and compression spring.
  10. REMOVE MASTER CYLINDER SOLENOID 
    1. Remove the 6 bolts and master cylinder solenoid.
      GTY596080Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the gasket.
      GTY215931Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. 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.
      GTY221203Courtesy 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.
      GTY596068Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE MASTER CYLINDER BOOT 
  13. REMOVE BRAKE BOOSTER PISTON SUB-ASSEMBLY 
    1. Pressing the piston in with a screwdriver, use a pin or equivalent to push the C-ring from the hole in the master cylinder body and then remove it with another screwdriver.
      GTY703597Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 C-Ring
      *2 Pin

      HINT: 

      Tape the screwdriver tip before use.

    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.

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