HYDRAULIC BRAKE BOOSTER (for LHD) DISASSEMBLY


  1. REMOVE NO. 1 BRAKE ACTUATOR BRACKET


    1. A015CER

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

    2. A015DDQ

      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. A0155WME01

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

    2. A0155SK

      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. A0158K7

      Remove the 3 reservoir grommets from the master cylinder reservoir.

  4. REMOVE NO. 1 BRAKE ACTUATOR HOSE


    1. A0156C6

      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. A0156JRE01

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

  6. REMOVE BRAKE BOOSTER WITH ACCUMULATOR PUMP ASSEMBLY


    1. A015C47E01

      Using a screwdriver, remove the 2 plugs.

    2. A015AYWE02

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

    3. A015DS8

      Using a screwdriver, remove the clip.

    4. A015CDJE01

      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. A015AE5E03

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

  7. REMOVE NO. 1 BRAKE BOOSTER PUMP BRACKET


    1. A01582HE02

      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. A0159EE

      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. A0159XDE02

      Remove the 6 bolts and master cylinder solenoid.

    2. A015D1A

      Remove the gasket.

  10. REMOVE MASTER CYLINDER PUSH ROD CLEVIS


    1. A015D3B

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

    2. A015DFVE02

      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. A015DNTE03

      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.