BRAKE BOOSTER (for LHD) REMOVAL

Note


  • Do not adjust the brake booster push rod.

  • Completely bleed the vacuum from inside the brake booster by depressing the brake pedal several times because the piston of the master cylinder is forced out of the master cylinder due to the pressure inside.


  1. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY

    Click here

  2. REMOVE BATTERY CLAMP SUB-ASSEMBLY


    1. A0135TU

      Remove the 3 bolts and the battery clamp sub-assembly.

  3. REMOVE BRAKE ACTUATOR ASSEMBLY (w/o VSC)

    A0136AIE01

    1. Pull the lock lever upward and disconnect the brake actuator connector.

      Text in Illustration
      *1 Lock Lever

      Note

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

    2. A0137WL

      Using a union nut wrench 10 mm, separate the 6 brake tubes from the brake actuator assembly.

    3. A0137P4E01
      Text in Illustration
      *A for LHD
      *B for RHD
      *a To front wheel cylinder RH
      *b To front wheel cylinder LH
      *c To rear wheel cylinder RH
      *d To rear wheel cylinder LH
      *e From 1st master cylinder
      *f From 2nd master cylinder

      Use tags or labels to identify the place to reconnect each brake tube.

    4. A013775

      Remove the 2 bolts and the brake actuator with bracket.

      Note

      Do not damage the brake tubes.

  4. REMOVE BRAKE ACTUATOR ASSEMBLY (w/ VSC)

    A0137L4E02

    1. Disengage the wire harness clamp.

      Text in Illustration
      *1 Lock Lever

      Note

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

    2. Pull the lock lever upward and disconnect the brake actuator connector.

    3. A01391A

      Using a union nut wrench 10 mm and a union nut wrench 12 mm, separate the 6 brake tubes from the brake actuator assembly.

      Text in Illustration
      A0137RP Flare Nut 10 mm
      A013859 Flare Nut 12 mm
    4. A0136JPE01
      Text in Illustration
      *A for LHD
      *B for RHD
      *a To front wheel cylinder RH
      *b To front wheel cylinder LH
      *c To rear wheel cylinder RH
      *d To rear wheel cylinder LH
      *e From 1st master cylinder
      *f From 2nd master cylinder

      Use tags or labels to identify the place to reconnect each brake tube.

    5. Disengage the fuel tube clamp from the brake actuator bracket assembly.

    6. A0137US

      Remove the 3 bolts and the brake actuator with bracket.

      Note

      Do not damage the brake tubes.

  5. SEPARATE MASTER CYLINDER PUSH ROD CLEVIS

    A0135YT

    1. Remove the clip and push rod pin, and separate the push rod clevis.

  6. REMOVE BRAKE BOOSTER ASSEMBLY

    A0136CY

    1. Separate the vacuum hose assembly from the brake booster assembly.

    2. A0138LM

      Remove the 4 nuts and the brake booster assembly.

    3. Remove the gasket from the brake booster assembly.

  7. REMOVE CHECK VALVE GROMMET

    A0138V3

    1. Remove the check valve grommet from the brake booster assembly.

  8. REMOVE MASTER CYLINDER PUSH ROD CLEVIS


    1. Loosen the lock nut and remove the master cylinder push rod clevis from the brake booster assembly.