Toyota 44610-52331
Brake Booster

Before working on the vacuum brake booster personnel should disconnect the battery terminal cable then wait for at least 90 seconds before continuing to avoid activating Air Bags and seat belt pretensioners. Empty out all brake fluid from the system while properly cleaning paint touched fluid away from the surface. The service begins by removing the air cleaner cap assembly while disconnecting the clutch reservoir tube by sliding its clip. After breaking the brake master cylinder subassembly one should remove the battery. The brake booster assembly installation requires disconnection of the vacuum hose by sliding the clip followed by removal of the brake pedal return spring, its clip and clevis pin then loosening the push rod clevis lock nut and removing the 4 nuts and push rod clevis and pulling out the brake booster and gasket. Installation requires first placing the new gasket along with the brake booster followed by tightening the four nuts to 13 Nm (127 kgf-cm, 9 ft. lbs.). Next, install the push rod clevis to the booster while applying lithium soap base glycol grease to the clevis pin before fastening the clip and clevis pin with correct positioning. The brake pedal return spring needs installation while the vacuum hose attachment to brake booster should happen before moving the clip into position. You should install brake actuator assembly with bracket before moving on to the brake master cylinder subassembly. After inserting the clutch reservoir tube clip you should install the air cleaner cap sub-assembly and the battery. Brake fluid goes into the reservoir before the technician removes air from the brake master cylinder and brake line and clutch line and adjusts brake pedal height and free play and reserve distance and checks the reservoir fluid level and brake fluid leaks. The initialization process also requires checking the brake actuator through the intelligent tester because some systems need initialization following negative battery terminal cable changes.

The first step for Vacuum Brake Booster replacement requires draining brake fluid while immediately cleaning off paint when fluid adheres to painted surfaces. After removing the sub-assembly of the air cleaner cap disconnect the clutch reservoir tube by sliding the clip. The assembly requires Special Service Tool: 09023-00100 to remove the brake master cylinder before continuing with removal of the battery and brake actuator with bracket and brake booster assembly. The brake booster assembly removal begins with removing its vacuum hose by sliding the clip then discontinuing the brake pedal return spring and clip and clevis pin before loosening the push rod clevis lock nut and separating the four nuts and push rod clevis to extract the assembly along with its gasket. Install the brake booster assembly with a new gasket by fastening it with the four nuts and push rod clevis and torquing them to 13 Nm (130 kgf-cm, 9 ft. lbs.). The procedure requires lithium soap base glycol grease on the clevis pin before installing the clip and clevis pin so that the clip is placed correctly according to the illustration. Fasten the brake pedal return spring then attach the brake booster assembly vacuum hose. Follow this procedure when checking the brake booster push rod without vacuum by repeating pedal brake depression when the engine is off. The accessory tool used to measure push rod clearance should have chalk placed on its tip to check the 0 mm (0 inch) gap against the brake booster assembly. Special Service Tool: should be utilized to both secure the push rod and adjust the length of the protruding adjusting bolt when the brake pedal reaches minimum depression. The installation process requires service tool 09023-00100 to properly fit the brake master cylinder between the brake actuator with bracket while the clutch reservoir tube will link through clip insertion. Reinstall the air cleaner cap sub-assembly and the battery before filling the reservoir with brake fluid and bleeding the master cylinder and brake lines and clutch pipe line for M/T transaxle. Adjustments should be made to the brake pedal height and free play and also include a check of the reservoir fluid level as well as brake fluid leakage and the performance of the brake actuator using a hand-held tester.

Remove the air cleaner cap sub-assembly, disconnect the clutch reservoir tube (M/T transaxle), and remove the brake master cylinder using Special Service Tool: 09023-00100.