BRAKE ACTUATOR(for RHD) REMOVAL

CAUTION / NOTICE / HINT

Note

Make sure to release vacuum from the brake booster assembly before removing the brake master cylinder sub-assembly from the brake booster assembly.

PROCEDURE


  1. PRECAUTION

    Note

    After turning the engine switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work.

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  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

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  3. REMOVE FRONT WHEEL RH

  4. DRAIN BRAKE FLUID

    Note

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

  5. SEPARATE NO. 3 ENGINE ROOM RELAY BLOCK ASSEMBLY

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  6. REMOVE WIRING HARNESS CLAMP BRACKET

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  7. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY

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  8. REMOVE BRAKE MASTER CYLINDER O-RING

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  9. REMOVE FRONT NO. 2 BRAKE TUBE


    1. B003X2DC02
      *a From 1st Chamber of Brake Master Cylinder Sub-assembly
      *b From 2nd Chamber of Brake Master Cylinder Sub-assembly
      *c To Front Wheel Cylinder Assembly RH
      *d To Front Wheel Cylinder Assembly LH
      *e To Rear Wheel Cylinder Assembly RH
      *f To Rear Wheel Cylinder Assembly LH

      Use tags or make a memo to identify the places to reconnect the brake lines.

    2. B003UE2

      Using a union nut wrench, disconnect the front No. 2 brake tube from the brake actuator assembly.

    3. Disengage the clamp.

    4. B003UA5C01
      *1 Front Flexible Hose
      *2 Grommet

      Using a union nut wrench, disconnect the front No. 2 brake tube from the front flexible hose.

    5. Disengage the grommet and remove the front No. 2 brake tube.

      Note


      • Do not kink or damage the front No. 2 brake tube.

      • Do not allow any foreign matter such as dirt or dust to enter the front No. 2 brake tube from the connecting parts.

  10. DISCONNECT UNION TO CHECK VALVE HOSE


    1. B003U85

      Slide the clip and disconnect the union to check valve hose from the brake booster assembly.

  11. REMOVE FRONT NO. 1 BRAKE TUBE


    1. B003VE6

      Using a union nut wrench, disconnect the front No. 1 brake tube from the brake actuator assembly.

    2. Disengage the clamp to remove the front No. 1 brake tube.

      Note


      • Do not kink or damage the front No. 1 brake tube.

      • Do not allow any foreign matter such as dirt or dust to enter the brake lines from the connecting parts.

  12. REMOVE FRONT NO. 5 BRAKE TUBE


    1. B003UYQ

      Using a union nut wrench, disconnect the front No. 5 brake tube from the brake actuator assembly.

    2. Disengage the clamp to remove the front No. 5 brake tube.

      Note


      • Do not kink or damage the front No. 5 brake tube.

      • Do not allow any foreign matter such as dirt or dust to enter the brake lines from the connecting parts.

  13. REMOVE BRAKE ACTUATOR WITH BRACKET


    1. Type A:


      1. B003W62C01
        B003UAS Release the lock lever

        Release the lock lever and disconnect the connector from the brake actuator assembly.

        Note

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

    2. Type B:


      1. B003V03C01
        B003UAS Release the lock lever
        B003VQQ Disconnect the connector

        Release the lock lever and disconnect the connector from the brake actuator assembly.

        Note

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

    3. B003SZR

      Using a union nut wrench, disconnect the 3 brake lines from the brake actuator assembly.

    4. B003SXD

      Remove the 2 bolts, nut and brake actuator with bracket.

      Note


      • Do not damage the brake lines.

      • Do not hold the brake actuator assembly by the connector.

      Tech Tips

      Remove the brake actuator with bracket while avoiding the brake lines.

  14. REMOVE BRAKE ACTUATOR ASSEMBLY


    1. B003UR2

      Remove the 3 bolts and brake actuator assembly from the brake actuator bracket assembly.

  15. REMOVE BRAKE ACTUATOR BOLT CUSHION


    1. B003V1NC02
      *1 Brake Actuator Case Collar
      *2 Brake Actuator Bolt Cushion

      Remove the 3 brake actuator case collars from the brake actuator bolt cushions.

    2. Remove the 3 brake actuator bolt cushions from the brake actuator bracket assembly.