BRAKE BOOSTER REMOVAL

Note

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


  1. REMOVE FRONT WHEEL

  2. REMOVE ENGINE ASSEMBLY


    1. for 1AZ-FE:

      Remove the engine assembly Click here.

    2. for 1ZR-FAE:

      Remove the engine assembly Click here.

    3. for 2ZR-FAE:

      Remove the engine assembly Click here.

    4. for 3ZR-FE:

      Remove the engine assembly Click here.

    5. for 3ZR-FAE:

      Remove the engine assembly Click here.

  3. DRAIN BRAKE FLUID

    Note

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

  4. REMOVE BRAKE ACTUATOR ASSEMBLY


    1. w/ VSC:

      Remove the brake actuator assembly Click here.

    2. w/o VSC:

      Remove the brake actuator assembly Click here.

  5. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY


    1. Remove the brake master cylinder sub-assembly Click here.

  6. REMOVE BRAKE PEDAL RETURN SPRING


    1. A00DTS1E01

      Remove the brake pedal return spring from the brake pedal support sub-assembly.

  7. REMOVE PUSH ROD PIN


    1. A00DRWUE01

      Remove the clip and push rod pin from the brake pedal lever.

  8. DISCONNECT BRAKE MASTER CYLINDER PUSH ROD CLEVIS


    1. Loosen the brake master cylinder push rod clevis lock nut.

    2. Disconnect the push rod clevis.

  9. DISCONNECT VACUUM HOSE


    1. A00DQMNE01

      Slide the clip and disconnect the vacuum hose.

  10. REMOVE BRAKE VACUUM CHECK VALVE ASSEMBLY


    1. Remove the vacuum check valve assembly from the brake booster assembly.

  11. REMOVE CHECK VALVE GROMMET


    1. Remove the check valve grommet from the brake booster assembly.

  12. REMOVE FRONT BRAKE LINE


    1. for LHD:


      1. A00DUIU

        Using a union nut wrench, disconnect the brake tube from the brake flexible hose LH.

      2. Remove the bolt and clamp from the body.

      3. A00DPOY

        Using a union nut wrench, disconnect the brake tube from the brake flexible hose RH.

      4. A00DU1O

        Remove the grommet and brake tube from the body.

      5. A00DREF

        Remove the 2 brake tube clamps from the body.

        Note

        The clamp cannot be reused after it is disconnected from the body.

      6. A00DQRCE01

        Using a union nut wrench, disconnect the 2 brake tubes from the 2-way.

      7. A00DS9Z

        Disconnect the brake tube clamp from the brake actuator bracket.

        Note

        The clamp cannot be reused after it is disconnected from the bracket.

    2. for RHD:


      1. A00DUIU

        Using a union nut wrench, disconnect the brake tube from the brake flexible hose LH.

      2. Remove the bolt and clamp from the body.

      3. A00DPOY

        Using a union nut wrench, disconnect the brake tube from the brake flexible hose RH.

      4. A00DU1O

        Remove the grommet and brake tube from the body.

      5. A00DPS4

        Remove the clamp from the body.

        Note

        The clamp cannot be reused after it is disconnected from the body.

      6. A00DUT6E01

        Remove the clamp from the body.

        Note

        The clamp cannot be reused after it is disconnected from the body.

      7. A00DRQG

        Using a union nut wrench, disconnect the 2 brake tubes from the 2-way.

      8. A00DS9Z

        Disconnect the brake tube clamp from the brake actuator bracket.

        Note

        The clamp cannot be reused after it is disconnected from the bracket.

  13. REMOVE BRAKE BOOSTER ASSEMBLY


    1. Remove the 4 nuts and brake booster assembly from the body.

      Tech Tips

      Model Washer Size
      Type A 15.5 mm (0.610 in.)
      Type B 20.0 mm (0.787 in.)

      • The sizes of washers are different for Type A and Type B.

      • The washers for Type A are smaller, and the washers for Type B are bigger.

      A00DV33E01

      Note

      Do not damage the brake lines or fuel lines.

  14. REMOVE BRAKE BOOSTER GASKET


    1. Remove the brake booster gasket from the brake booster assembly.

  15. REMOVE BRAKE MASTER CYLINDER PUSH ROD CLEVIS


    1. Loosen the lock nut and remove the brake master cylinder push rod clevis and lock nut from the brake booster assembly.