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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/o Vacuum Brake Booster) >> Removal [02/2019 - 10/2019] >> Procedure

Removal [02/2019 - 10/2019]: Procedure

  1. PRECAUTION 
    WARNING:

    Be sure to read precaution thoroughly before servicing.

    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. DISABLE BRAKE CONTROL 

    Refer to PROCEDURE - Step 5

  3. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    Refer to REMOVAL [11/2018 - ]

  4. REMOVE COWL VENTILATOR PANEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 8

  5. DRAIN BRAKE FLUID 
    NOTE:

    If brake fluid leaks onto any painted surface, immediately wash it off.

  6. REMOVE LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY 

    Refer to REMOVAL [02/2019 - 10/2019]

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

    Refer to PROCEDURE - Step 19

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

    Refer to PROCEDURE - Step 20

  9. REMOVE STOP LIGHT SWITCH ASSEMBLY 

    Refer to REMOVAL [11/2018 - ]

  10. REMOVE BRAKE PEDAL RETURN SPRING 

    Refer to PROCEDURE - Step 9

  11. SEPARATE WIRE HARNESS 
    1. GTY937398Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Disconnect the connector from the brake pedal stroke sensor assembly.

    2. Disengage the 2 clamps to separate the wire harness from the brake pedal support assembly.
  12. REMOVE PUSH ROD PIN 

    Refer to PROCEDURE - Step 10

  13. SEPARATE BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY 
    1. Remove the 2 nuts and separate the brake master cylinder reservoir assembly.
      GTY882552Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. DISCONNECT NO. 2 RESERVOIR HOSE 
    1. Slide the clip and disconnect the No. 2 reservoir hose from the brake booster with master cylinder assembly.
      GTY935936Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. DISCONNECT NO. 1 RESERVOIR HOSE 
    1. Slide the clip and disconnect the No. 1 reservoir hose from the brake booster with master cylinder assembly.
      GTY882555Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. DISCONNECT NO. 1 BRAKE ACTUATOR HOSE 
    1. Slide the clip and disconnect the brake actuator hose from the brake master cylinder reservoir assembly.
      GTY935935Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE BRAKE MASTER CYLINDER RESERVOIR WITH RESERVOIR HOSE 
    1. Remove the brake master cylinder reservoir with reservoir hose
  18. REMOVE RESERVOIR BRACKET 
    1. GTY882553Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Remove the bolt, 2 nuts and reservoir bracket.

  19. SEPARATE NO. 1 BRAKE ACTUATOR TUBE 
    1. Remove the 2 nuts and separate the No. 1 brake actuator tube from the vehicle body.
      GTY935922Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. DISCONNECT NO. 4 FRONT BRAKE TUBE 
    1. Using a union nut wrench, disconnect the No. 4 front brake tube.
      GTY882496Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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.
  21. REMOVE BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY 
    1. Disengage the clamp to separate the wire harness.
      GTY885675Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Release the lock lever
      Disconnect the connector
    2. Release the lock lever and disconnect the connector from the brake booster with master cylinder assembly.
      NOTE:

      Be careful not to allow brake fluid to enter the removed connector.

    3. Using a union nut wrench, disconnect the 5 brake lines from the brake booster with master cylinder assembly.
      GTY886007Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a To Front Wheel Cylinder LH
      *b To Rear Wheel Cylinder RH
      *c To Brake Booster Pump Assembly
      *d To Rear Wheel Cylinder LH
      *e To Front Wheel Cylinder RH
    4. Use tags or make a memo to identify the places to reconnect.
    5. Disengage the 8 clamps to remove the 2 brake tube clamps from the brake lines.
      GTY882495Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. GTY889089Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Disengage the 4 clamps to remove the brake tube clamp from the brake lines.

    7. Disengage the clamp and remove the brake tube clamp from the vehicle body.
    8. Disengage the clamp to remove the No. 4 front brake tube with brake tube clamp from the brake line.
      GTY889090Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Disengage the clamp to remove the brake tube clamp from the No. 4 front brake tube.
      GTY882491Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Remove the 4 nuts and brake booster with master cylinder assembly.
      GTY921977Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Connector Portion
      *2 Union
      *3 Push Rod Clevis
      *4 Boot
      *5 Front No. 2 Brake Tube
      NOTE:
      • Do not kink or damage the brake lines.
      • Do not carry the brake booster with master cylinder assembly by the portion shown in the illustration.
  22. REMOVE BRAKE BOOSTER GASKET 
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