BRAKE MASTER CYLINDER REMOVAL

CAUTION / NOTICE / HINT

Note

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

PROCEDURE


  1. DRAIN BRAKE FLUID

    Note

    Wash off brake fluid immediately if it comes in contact with any painted surface.

  2. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY (for 2TR-FE)


    1. for Manual Transmission:

      Slide the clip and disconnect the clutch reservoir tube from the brake master cylinder sub-assembly.

      B003LC9C01
      *A for LHD *B for RHD

    2. Disconnect the brake fluid warning switch connector.

    3. Using a union nut wrench, disconnect the 2 brake lines from the brake master cylinder sub-assembly.

      Note


      • Do not damage or deform the brake lines.

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

    4. Disconnect the brake booster vacuum ejector.

      Click here

    5. for LHD:

      Remove the bolt and booster vacuum tube from the brake booster tube clamp bracket.

    6. Remove the 3 nuts, brake booster tube clamp bracket and reservoir hose bracket.

      B003O72C01
      *A for LHD *B for RHD

    7. Pull out the brake master cylinder sub-assembly from the brake booster assembly.

      Note


      • The master cylinder requires careful handling. Do not allow the master cylinder to receive any impact, such as from being dropped. Do not reuse a master cylinder that has been dropped.

      • Do not strike or pinch the master cylinder piston, and do not cause any damage to the master cylinder piston by any other means.

      • When installing the master cylinder to the brake booster or removing the master cylinder from the brake booster, make sure that the master cylinder kept horizontal or with its tip facing downward (the piston faces upward) to prevent the master cylinder piston from falling out.

      • Do not allow any foreign objects to contaminate the master cylinder piston. If a foreign object gets on the piston, remove it by using a piece of cloth, and then apply an even layer of lithium soap base glycol grease around the circumference (sliding part) of the piston.

      • Do not use any other type of grease or fluid.

      • Be careful not to damage the brake lines.

    8. Remove the O-ring from the brake master cylinder sub-assembly.

  3. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY (for Diesel)


    1. for Manual Transmission:

      Slide the clip and disconnect the clutch reservoir tube from the brake master cylinder sub-assembly.

      B003MHKC01
      *A for LHD *B for RHD

    2. Disconnect the brake fluid warning switch connector.

    3. Using a union nut wrench, disconnect the 2 brake lines from the brake master cylinder sub-assembly.

      Note


      • Do not damage or deform the brake lines.

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

    4. Remove the 2 nuts and brake booster tube clamp bracket.

      B003M0WC01
      *A for LHD *B for RHD

    5. Pull out the brake master cylinder sub-assembly from the brake booster assembly.

      Note


      • The master cylinder requires careful handling. Do not allow the master cylinder to receive any impact, such as from being dropped. Do not reuse a master cylinder that has been dropped.

      • Do not strike or pinch the master cylinder piston, and do not cause any damage to the master cylinder piston by any other means.

      • When installing the master cylinder to the brake booster or removing the master cylinder from the brake booster, make sure that the master cylinder is kept horizontal or with its tip facing downward (the piston faces upward) to prevent the master cylinder piston from falling out.

      • Do not allow any foreign objects to contaminate the master cylinder piston. If a foreign object gets on the piston, remove it by using a piece of cloth, and then apply an even layer of lithium soap base glycol grease around the circumference (sliding part) of the piston.

      • Do not use any other type of grease or fluid.

      • Be careful not to damage the brake lines.

    6. Remove the O-ring from the brake master cylinder sub-assembly.

  4. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY (for 1GR-FE)


    1. Disconnect the brake fluid warning switch connector.

      B003SA3C01
      *A for LHD *B for RHD

    2. Using a union nut wrench, disconnect the 2 brake lines from the brake master cylinder sub-assembly.

      Note


      • Do not damage or deform the brake lines.

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

    3. Remove the 2 nuts and brake booster tube clamp bracket.

      B003ND2C01
      *A for LHD *B for RHD

    4. Pull out the brake master cylinder sub-assembly from the brake booster assembly.

      Note


      • The master cylinder requires careful handling. Do not allow the master cylinder to receive any impact, such as from being dropped. Do not reuse a master cylinder that has been dropped.

      • Do not strike or pinch the master cylinder piston, and do not cause any damage to the master cylinder piston by any other means.

      • When installing the master cylinder to the brake booster or removing the master cylinder from the brake booster, make sure that the master cylinder is kept horizontal or with its tip facing downward (the piston faces upward) to prevent the master cylinder piston from falling out.

      • Do not allow any foreign objects to contaminate the master cylinder piston. If a foreign object gets on the piston, remove it by using a piece of cloth, and then apply an even layer of lithium soap base glycol grease around the circumference (sliding part) of the piston.

      • Do not use any other type of grease or fluid.

      • Be careful not to damage the brake lines.

    5. Remove the O-ring from the brake master cylinder sub-assembly.