HYDRAULIC BRAKE BOOSTER(for RHD) DISASSEMBLY

PROCEDURE


  1. REMOVE NO. 1 BRAKE ACTUATOR BRACKET


    1. A01XEIT

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

    2. A01XKED

      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. A01XDAJE07
      Text in Illustration
      *1 Pin Punch

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

    2. A01XMCU

      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. A01XLBJ

      Remove the 3 reservoir grommets from the master cylinder reservoir.

  4. REMOVE NO. 1 BRAKE ACTUATOR HOSE


    1. A01XI1I

      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. A01XKQL

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

  6. REMOVE BRAKE BOOSTER WITH ACCUMULATOR PUMP ASSEMBLY


    1. A01XFMA

      Using a screwdriver, remove the 2 plugs.

    2. A01XJ95

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

    3. A01XEYI

      Using a screwdriver, remove the clip.

    4. A01XLKA

      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. A01XHP6

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

  7. REMOVE NO. 1 BRAKE BOOSTER PUMP BRACKET


    1. A01XI43

      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. A01XKTP

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

  9. REMOVE BRAKE BOOSTER ACCUMULATOR PIPE


    1. A01XM95

      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. A01XIQF

      Remove the 6 bolts and master cylinder solenoid.

    2. A01XDVZ

      Remove the gasket.

  11. REMOVE MASTER CYLINDER PUSH ROD CLEVIS


    1. A01XI9B

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

    2. A01XGRR

      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. A01XKE1E18
      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.