BRAKE ACTUATOR REMOVAL


  1. PRECAUTION

    Note

    After turning the engine switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work Click here.

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

  3. REMOVE FRONT WHEEL

  4. REMOVE ENGINE ROOM SIDE COVER LH


    1. A01FH9C

      Detach the 2 clips and remove the engine room side cover LH.

  5. DRAIN BRAKE FLUID

    Note

    Wash off brake fluid immediately if it comes into contact with a painted surface.

  6. REMOVE FRONT NO. 2 BRAKE TUBE (for RHD)


    1. A01FD8E

      Using a union nut wench, disconnect the No. 2 front brake tube.

    2. Hold the flexible hose in place with a wrench, and disconnect the No. 2 brake tube from the flexible hose using the union nut wrench.

    3. Remove the grommet and No. 2 brake tube from the vehicle.

      Note

      Do not deform or damage the brake tube.

  7. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY (for RHD)


    1. Disconnect the brake fluid level warning switch connector.

    2. A01FGDE

      for LHD:

      Detach the clamp.

    3. A01FIKY

      for RHD:

      Detach the clamp.

    4. A01FI0L

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

    5. A01FEBE

      for LHD:

      Remove the 2 nut and brake master cylinder from the brake booster.

      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 tubes.

    6. A01FGX9

      for RHD:

      Remove the 2 nuts and disconnect the harness clamp bracket and brake master cylinder.

      Tech Tips

      Remove the parts while avoiding the brake actuator 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 tubes.

    7. Remove the O-ring from the master cylinder.

  8. REMOVE BRAKE ACTUATOR WITH BRACKET


    1. Release the lock lever and disconnect the brake actuator connector.

      A01FD90E01
      Text in Illustration
      *A for LHD *B for RHD

      Note

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

    2. for LHD:

      Using a union nut wrench, disconnect the 6 brake lines from the brake actuator.

    3. for RHD:

      Using a union nut wrench, disconnect the 5 brake lines from the brake actuator.

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

      A01FEDUE01
      Text in Illustration
      *A for LHD *B for RHD

      Tech Tips


      • *1: to front wheel cylinder RH

      • *2: to front wheel cylinder LH

      • *3: to rear wheel cylinder RH

      • *4: to rear wheel cylinder LH

      • *5: from front master cylinder

      • *6: from rear master cylinder

    5. Remove the 2 bolts, nut and actuator assembly with bracket from the body.

      A01FEK7E01
      Text in Illustration
      *A for LHD *B for RHD

      Note

      Do not damage the brake tubes.

  9. REMOVE NO. 5 BRAKE ACTUATOR BRACKET


    1. Remove the bolt and No. 5 brake actuator bracket from the body.

      A01FGC2E01
      Text in Illustration
      *A for LHD *B for RHD