HYDRAULIC BRAKE BOOSTER (for RHD) DISASSEMBLY


  1. REMOVE NO. 1 BRAKE ACTUATOR BRACKET


    1. A01DUBP

      Using a 5 mm hexagon wrench, remove the bolt and No. 1 brake actuator bracket.

    2. A01DP5J

      Using a screwdriver, disconnect the brake fluid level warning switch connector from the No. 1 brake actuator bracket.

  2. REMOVE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY


    1. A01DU8UE03
      Text in Illustration
      *1 Pin Punch

      Using a pin punch and hammer, remove the pin from the brake master cylinder reservoir.

    2. A01DMK3

      Remove the screw and pull out the brake master cylinder reservoir sub-assembly.

    3. Remove the master cylinder reservoir filler cap.

  3. REMOVE MASTER CYLINDER RESERVOIR GROMMET


    1. A01DR44E01

      Remove the 3 reservoir grommets from the master cylinder reservoir.

  4. REMOVE NO. 1 BRAKE ACTUATOR HOSE


    1. A01DSMRE02

      Using needle nose pliers, slide the 2 clips and remove the brake actuator hose and 2 clips.

  5. REMOVE NO. 1 BRAKE ACTUATOR TUBE


    1. A01DUNF

      Using a union nut wrench, remove the No. 1 brake actuator tube.

  6. REMOVE BRAKE BOOSTER WITH ACCUMULATOR PUMP ASSEMBLY


    1. A01DO25E01

      Using a screwdriver, remove the 2 plugs.

    2. A01DO75E02

      Remove the 2 screws and disconnect the wire harnesses from the master cylinder solenoid.

    3. A01DUL6

      Using a screwdriver, remove the clip.

    4. A01DR5BE01

      Remove the brake booster with accumulator pump assembly from the brake master cylinder.

    5. Remove the 2 brake booster pump collars and 2 brake booster pump bushes from the brake booster with accumulator pump assembly.

    6. A01DTT7E03

      Using a 4 mm hexagon wrench, remove the 2 pins.

  7. REMOVE NO. 1 BRAKE BOOSTER PUMP BRACKET


    1. A01DO4JE02

      Using a 5 mm hexagon wrench, remove the 2 bolts and No. 1 brake booster pump bracket from the brake master cylinder solenoid.

    2. Remove the brake booster pump bush from the No. 1 brake booster pump bracket.

  8. REMOVE NO. 3 BRAKE ACTUATOR BRACKET


    1. A01DU1M

      Remove the bolt and No. 3 brake actuator bracket from the brake master cylinder.

  9. REMOVE BRAKE BOOSTER ACCUMULATOR PIPE


    1. A01DOC7

      Secure the brake booster with accumulator pump assembly in a vise.

    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. A01DMTUE02

      Remove the 6 bolts and master cylinder solenoid.

    2. A01DRR8

      Remove the gasket.

  11. REMOVE MASTER CYLINDER PUSH ROD CLEVIS


    1. A01DQ1Q

      Loosen the lock nut on the rod operating adapter and remove the push rod clevis and lock nut.

    2. A01DSN8E02

      Loosen the lock nut on the brake master cylinder side and remove the rod operating adapter and lock nut.

  12. REMOVE MASTER CYLINDER BOOT

  13. REMOVE BRAKE BOOSTER PISTON SUB-ASSEMBLY


    1. A01DS20E05
      Text in Illustration
      *1 C-Ring
      *2 Pin

      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.

      Tech Tips

      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.

    2. Remove the plug from the piston.

    3. Remove the piston by pulling it straight out, not at an angle.

      Note

      If the piston pulled out at an angle, there is a possibility that the cylinder bore could be damaged.