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Home >> Toyota >> 2021 >> RAV4 XLE, AWD >> Repair and Diagnosis >> Brakes >> Mechanical - Hydraulic >> Brake System (Hydraulic) - Service Information (2 Of 2) >> BRAKE BOOSTER (w/ Vacuum Brake Booster) >> Removal [08/2020 - 12/2021] >> Procedure

Removal [08/2020 - 12/2021]: Procedure

  1. PRECAUTION 
    WARNING:

    Be sure to read precaution thoroughly before servicing.

    Refer to PRECAUTION [08/2020 - ]

    GTY824211Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

    Refer to PRECAUTION [11/2018 - ]

  2. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY 

    Refer to REMOVAL [08/2020 - 10/2022]

  3. REMOVE ECM 

    Refer to REMOVAL [08/2020 - 10/2022]

  4. REMOVE BATTERY CLAMP SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 25

  5. REMOVE LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY 

    Refer to REMOVAL [08/2020 - 12/2021]

  6. REMOVE NO. 1 AIR DUCT (for TMC Made) 

    Refer to PROCEDURE - Step 19

  7. REMOVE NO. 2 AIR DUCT SUB-ASSEMBLY (for TMMC Made) 

    Refer to PROCEDURE - Step 20

  8. REMOVE STOP LIGHT SWITCH ASSEMBLY 

    Refer to PROCEDURE - Step 2

  9. REMOVE BRAKE PEDAL RETURN SPRING 

    Refer to PROCEDURE - Step 8

  10. SEPARATE WIRE HARNESS 
    1. Disconnect the connector.
      GTY874562Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the 2 clamps to separate the wire harness from the brake pedal support assembly.
  11. LOOSEN LOCK NUT 
    1. Loosen the lock nut of the brake master cylinder push rod clevis.
      GTY890835Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Lock Nut
      *2 Brake Master Cylinder Push Rod Clevis
  12. REMOVE PUSH ROD PIN 

    Refer to PROCEDURE - Step 10

  13. DISCONNECT CHECK VALVE TO CONNECTOR TUBE HOSE 
    1. Slide the clip and disconnect the check valve to connector tube hose from the brake booster assembly.
      GTY874724Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE BRAKE BOOSTER ASSEMBLY 
    1. Remove the bolt and nut.
      GTY874725Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the guide and separate the wire harness.
    3. Apply protective tape to the vehicle body as shown in the illustration.
      GTY895777Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Protective Tape
    4. Disconnect the connector from the vacuum warning switch assembly.
      GTY874723Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. w/ Stop and Start System:
      GTY874729Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Disconnect the connector from the vacuum sensor assembly.
    6. Disengage the 5 clamps to separate the brake tube clamp from the brake lines.
      GTY874715Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Disengage the 5 clamps to remove the brake tube clamp from the brake lines.
      GTY874716Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Disengage the 5 clamps to remove the brake tube clamp from the brake lines.
      GTY874720Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. GTY934210Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Disengage the 3 clamps to separate the brake tube clamp from the brake lines.

    10. Remove the bolt and clamp to remove the 2 brake tube clamps from the vehicle body.
      GTY934209Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    11. Using a union nut wrench, remove the 2 brake lines from the brake actuator assembly.
      GTY884593Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a From 1st Chamber of Brake Master Cylinder Sub-assembly
      *b From 2nd Chamber of Brake Master Cylinder Sub-assembly
      NOTE:
      • Do not kink or damage the brake lines.
      • Do not allow any foreign matter such as dirt or dust to enter the brake lines from the connecting parts.
    12. Remove the 4 nuts.
      GTY874721Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not apply excessive force to the brake lines.

    13. Remove the brake master cylinder push rod clevis and lock nut from the brake booster assembly.
    14. Remove the brake booster assembly from the vehicle body.
      NOTE:

      Do not apply excessive force to the brake lines.

  15. REMOVE BRAKE BOOSTER GASKET 
    1. Remove the brake booster gasket from the brake booster assembly.
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