Toyota 47201-06423
Master Cylinder

Energy-related accidents and impact damage should be avoided when handling the brake master cylinder because any drops will result in permanent damage. Keep the piston circumference unharmed because it affects seal performance and do not remove the piston from its position. A vacuum hose removal should precede any procedure to relieve brake booster vacuum. Supply grease through the TMC manufactured cylinders by removing protective measures from the piston and brake booster discharge port after which you should apply the supplied grease on the piston's outer diameter and brake booster's inner diameter. When installing or removing TMMK made master cylinders always handle them horizontally or with the tip below the horizontal plane to stop piston dislodgement and keep foreign matter away from the piston through the use of greasy shop rags and lithium soap-based glycol grease for the mobile portion. Start by draining brake fluid after turning off the engine and stepped on the brake pedal until all vacuum pressure runs out. Follow these steps: at first remove the air cleaner cap sub-assembly and air cleaner filter element sub-assembly then take out the front wiper arm sub-assembly and front blade assemblies from both sides of the vehicle; proceed with removing the front fender to cowl side seals from both sides and disassemble the cowl top ventilator louver sub-assembly and windshield wiper motor sub-assembly along with the cowl top outer front panel sub-assembly by separating the clamp and removing its 4 nuts and 4 bolts. TMC brake master cylinder makes require a Special Service Tool: 09023-00101 for disconnecting 6 brake lines and a subsequent removal of the brake master cylinder to way tube before taking off the 2 nuts and front brake tube way and O-ring and brake master cylinder sub-assembly. The procedure for TMMK without VSC matches all TMC requirements. Special Service Tools 09023-38200 and 09023-00101 help disconnect the six brake lines from TMMK made with VSC through the connector before removing the brake master cylinder to way tube and front brake tube way with its O-ring and brake master cylinder sub-assembly.

The first step to remove the brake master cylinder requires shutting off the engine then pressing the brake pedal several times to release vacuum from the brake booster. Inspection of painted surfaces requires an immediate response when brake fluid appears. Drain brake fluid before disassembling the air cleaner cap sub-assembly, air cleaner filter element sub-assembly and the pairs of front wiper arm and blade assemblies (LH and RH). The next step requires removal of the front fender to cowl side seals from both LH and RH positions followed by taking out the cowl top ventilator louver sub-assembly and the windshield wiper motor and link assembly. The procedure requires disassembly of the front cowl top outer panel assembly by disconnecting its clamp followed by removing four nuts and four bolts. The branch tube leading to the clutch reservoir can be detached from the brake master cylinder sub-assembly through removing its clip. The brake master cylinder removal process for TMC-made vehicles begins by using Special Service Tool: 09023-00101 to remove the 6 brake lines and disconnect the connector. The technician then must remove the brake master cylinder to way tube before extracting the front brake tube way and O-ring with its two retaining nuts. Similar methods should be used for disassembly of TMMK made vehicles without VSC using the same steps as TMC made vehicles. The brake master cylinder sub-assembly removal process begins by using Special Service Tools 09023-38200 and 09023-00101 to disconnect the 6 brake lines followed by removing the brake master cylinder to way tube and then unfastening the 2 nuts, front brake tube way and O-ring of the TMMK-made vehicles with VSC.

The process to remove the Brake Master Cylinder starts with piston prevention by gripping either the body or reservoir section rather than touching the piston or risking any damage. Before brake booster removal the vacuum needs to be released while proper master cylinder positioning at either a horizontal orientation or downward facing position will prevent piston displacement during installation or removal. Combination of foreign materials with master cylinder piston requires immediate cleaning with a shop rag followed by application of uniformly spread lithium soap-based glycol grease on the piston circumference but never use alternative types of grease. Start by draining brake fluid and after engaging the engine off position depress the brake pedal multiple times to empty vacuum from the booster then wipe away leaking fluid from paint surfaces. Starting with the air cleaner cap removal along with its hose you should disconnect the connector and untie the clamp. To detach the brake lines, use a 10 mm union nut wrench and pull off six lines and remove the No. 1 front brake tube from the brake master cylinder sub-assembly. Unfasten the two nuts which secure the front brake tube way along with brake master cylinder sub-assembly from the brake booster assembly then remove the O-ring located in the brake master cylinder sub-assembly.

Fill the reservoir with brake fluid, bleed the brake master cylinder, bleed the brake line, and bleed the brake actuator (w/ VSC).

Install the cowl top outer front panel sub-assembly using 4 nuts and 4 bolts, with nut torque at 85 Nm (867 kgf-cm, 63 ft-lbf) and bolt torque at 5.0 Nm (51 kgf-cm, 44 in-lbf).

Fill the reservoir with brake fluid, bleed the brake master cylinder, bleed the brake line, and bleed the brake actuator.

Disconnect the clutch reservoir tube from the brake master cylinder sub-assembly, then remove the brake master cylinder sub-assembly for TMC made by disconnecting the connector, using Special Service Tool: 09023-00101 to disconnect the 6 brake lines, and remove the brake master cylinder to way tube, followed by removing the 2 nuts, front brake tube way, O-ring, and the brake master cylinder sub-assembly.

Connect the connector, then install the brake master cylinder to way tube and temporarily tighten the 6 brake lines.