Brake Booster ASSY: Replacement

DRAIN BRAKE FLUID
NOTE: Wash brake fluid off immediately if it comes into contact with any painted surface.
REMOVE AIR CLEANER CAP SUB-ASSY
REMOVE AIR CLEANER CASE SUB-ASSY
1. Remove the air cleaner element, then remove the 3 bolts and air cleaner case sub-assy.
REMOVE BRAKE MASTER CYLINDER SUB-ASSY (SEE OVERHAUL )
SST 09023-00100
DISCONNECT BRAKE MASTER CYLINDER PUSH ROD CLEVIS (SEE REPLACEMENT )
REMOVE CRUISE CONTROL ACTUATOR ASSY (W/ CRUISE CONTROL ACTUATOR)
1. Remove the 2 nuts and bolt from the cruise control actuator assy w/ bracket, and move the cruise control actuator assy w/ bracket aside.
  
  Fig 1: Separating Cruise Control Actuator Assy (W/ Cruise Control Actuator)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT WHEEL LH
REMOVE BRAKE BOOSTER ASSY
1. Using SST and spanner, disconnect the brake tube from the flexible hose, and remove the brake tube from the body.
  SST 09023-00100
2. Slide the clip and disconnect the vacuum hose from the brake booster assy.
  
  Fig 2: Disconnecting Front Brake Tube No.5
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Disconnect the 2 or 3 brake tubes from the clamp, and move the brake tubes aside.
  
  Fig 3: Separating 2 Or 3 Brake Tubes From Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the 4 nuts and push rod clevis.
5. Pull out the brake booster and gasket.
  
  Fig 4: Removing Brake Booster Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BRAKE BOOSTER ASSY
1. Install the clevis to the booster push rod.
2. Install a new gasket and brake booster with the 4 nuts.
  
  Fig 5: Installing Brake Booster Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Connect the 2 or 3 brake tubes to the clamp.
4. Connect the vacuum hose to the brake booster assy.
  
  Fig 6: Installing 2 Or 3 Brake Tubes To Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using SST and spanner, connect the brake tube to the flexible hose.
  SST 09023-00100
  
  Torque: 15.2 N.m (155 kgf.cm, 11 ft.lbf)
Fig 7: Connecting Front Brake Tube
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT WHEEL LH
Torque: 103 N.m (1,050 kgf.cm, 76 ft.lbf)
INSTALL CRUISE CONTROL ACTUATOR ASSY (W/ CRUISE CONTROL)
1. Install the cruise control actuator assy w/ bracket with 2 nuts and bolt.
  Torque: 43 N.m (438 kgf.cm, 32 ft.lbf)
  
  Fig 8: Installing Cruise Control Actuator Assy W/ Bracket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT BRAKE MASTER CYLINDER PUSH ROD CLEVIS (SEE REPLACEMENT )
INSTALL BRAKE MASTER CYLINDER SUB-ASSY (SEE OVERHAUL )
INSTALL AIR CLEANER CASE SUB-ASSY
1. Install the air cleaner case with 3 bolts, then install the air cleaner element to the air cleaner case sub-assy.
INSTALL AIR CLEANER CAP SUB-ASSY
FILL RESERVOIR WITH BRAKE FLUID (SEE BRAKE FLUID )
BLEED MASTER CYLINDER (SEE BRAKE FLUID )
SST 09023-00100
BLEED BRAKE LINE (SEE BRAKE FLUID )
CHECK AND ADJUST BRAKE PEDAL HEIGHT (SEE ADJUSTMENT )
CHECK PEDAL FREE PLAY (SEE ADJUSTMENT )
CHECK PEDAL RESERVE DISTANCE (SEE ADJUSTMENT )
CHECK FLUID LEVEL IN RESERVOIR (SEE BRAKE FLUID )
CHECK FOR BRAKE FLUID LEAKAGE