Toyota 44610-52051
Brake Booster

Service and repair of the Vacuum Brake Booster starts by disassembling master cylinder and air cleaner assembly and ABS actuator and separation of the brake booster vacuum hose. Start by taking the brake booster gasket out, then remove the brake booster after unscrewing its 4 installation nuts and clevis pins. Next, remove the return spring and clip and clevis pin from the system. Installation starts with adding the new gasket along with the booster before torquing the booster installation nuts to 13 Nm (130 kgf-cm, 9 ft. lbs.) and torquing the clevis and its lock nut to 26 Nm (260 kgf-cm, 19 ft. lbs.). Connect the clevis pin through the clevis before using the clip to secure it together with the brake pedal. Then reinstall the return spring. When replacing the brake master cylinder users must adjust the brake booster push rod length through a process of chalk application to an accessory tool and brake booster contact followed by measuring the tool clearance from the push rod to verify a 0 mm (0 inch) reading. The clearance should be precisely 0 mm (0 inch) so use Special Service Tool: 09737-00020 to allow you to adjust the push rod length and protruding adjusting bolt's length including booster vacuum-free depressions of the brake pedal with the engine turned off. Reconnect the brake booster vacuum hose after adjusting the device while also reinstalling the ABS actuator to reinstall the air cleaner assembly followed by the master cylinder installation. Finish the procedure by adding brake fluid to the reservoir and performing a brake system bleed. After completing the procedure check for leaks then verify and adjust the brake pedal before performing an operational check.

Begin all hydraulic brake booster servicing and repairs with an OFF ignition switch and more than 40 brake pedal depressions. The syringe procedure requires fluid removal while avoiding any contact between brake fluid and painted surfaces. First remove the top panel of the outer front cowl then disconnect the fluid level warning switch connector from the reservoir before removing its two bolts fastened with a Torque of 7.5 Nm. After that disconnect the 3 fluid hoses and extract the entire reservoir system with the attached hoses. First disconnect the 3 hoses from the reservoir bracket clamp before removing the 4 bolts from the reservoir bracket while tightening them to 18 Nm. The installation of Special Service Tool: 09023-00100 requires use with a spanner (Torque: 15 Nm) to extract the right front brake line with its attached grommet from the body. The brake line must be disconnected from the hydraulic brake booster assembly through the use of the same special service tool during installation (Torque: 15 Nm) while also removing 2 connectors. The removal process for the hydraulic brake booster assembly demands detachment of three bolts and a nut with 19 Nm torque then removal of the assembly along with two bolts and a sub bracket at 19 Nm torque. The installation procedure requires following the reverse order of removal while adding brake fluid to the reservoir then performing brake system bleeding and inspecting for leaks.

Check for leaks, verify and adjust the brake pedal, and perform an operational check.

Finally, connect the vacuum hose to the brake booster, install the ABS actuator, air cleaner assembly, and master cylinder, fill the brake reservoir with brake fluid, bleed the brake system, check for leaks, check and adjust the brake pedal, and perform an operational check.

Connect the vacuum hose to the brake booster, reinstall the ABS actuator, air cleaner assembly, and master cylinder, fill the brake reservoir with brake fluid, and bleed the brake system.

Use a syringe, taking care not to let brake fluid remain on painted surfaces.

Take off the 4 bolts securing it with a torque of 7.8 Nm (80 kgf-cm, 69 inch lbs.).