HYDRAULIC BRAKE BOOSTER(for LHD) DISASSEMBLY

PROCEDURE


  1. REMOVE NO. 1 BRAKE ACTUATOR BRACKET


    1. A01X20S

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

    2. A01X4U7

      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. A01X4GNE01
      *1 Pin Punch

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

    2. A01X803

      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. A01X3FR

      Remove the 3 reservoir grommets from the master cylinder reservoir.

  4. REMOVE NO. 1 BRAKE ACTUATOR HOSE


    1. A01X37Z

      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. A01X9QSE01
      *1 Union Nut Wrench

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

  6. REMOVE BRAKE BOOSTER WITH ACCUMULATOR PUMP ASSEMBLY


    1. A01X1S7

      Using a screwdriver, remove the 2 plugs.

    2. A01X6X0

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

    3. A01XB6L

      Using a screwdriver, remove the clip.

    4. A01X01G

      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. A01XBFA

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

  7. REMOVE NO. 1 BRAKE BOOSTER PUMP BRACKET


    1. A01X0IC

      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 BRAKE BOOSTER ACCUMULATOR PIPE


    1. A01XA1U

      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

      Ensure no foreign matter enters the pump.

    4. Remove the brake booster accumulator pipe and compression spring.

  9. REMOVE MASTER CYLINDER SOLENOID


    1. A01X5JQ

      Remove the 6 bolts and master cylinder solenoid.

    2. A01XB68

      Remove the gasket.

  10. REMOVE MASTER CYLINDER PUSH ROD CLEVIS


    1. A01X6VG

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

    2. A01X0YF

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

  11. REMOVE MASTER CYLINDER BOOT

  12. REMOVE BRAKE BOOSTER PISTON SUB-ASSEMBLY


    1. A01X3WUE13
      *1 C-Ring
      *2 Pin

      Pressing the piston in with a screwdriver, insert a pin or equivalent from the hole in the master cylinder body to hold the C-ring, and then remove it with another screwdriver.

      Tech Tips

      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.