Toyota 47201-06260
Master Cylinder

The first step for brake master cylinder servicing begins by draining brake fluid followed by immediately cleaning painted surfaces which became contaminated by fluid residue. Use Special Service Tool: 09023-00101 to disconnect six brake lines from the brake master cylinder after the brake master cylinder sub-assembly and air cleaner assembly removal by disconnecting the level warning switch connector. The 2 nuts need to be taken off before you remove the 2-way and brake master cylinder sub-assembly. The service technician should start by removing the master cylinder reservoir filler cap assembly along with the master cylinder reservoir strainer. To extract the master cylinder reservoir sub-assembly the screw must be unscrewed after which the installation of 2 master cylinder reservoir grommets should take place. To work on the brake master cylinder kit without VSC set the cylinder inside a vise before removing the O-ring while pushing the piston after which snap ring pliers will extract the snap ring. Push the piston inside once more to extract the bolt together with the gasket from the piston stopping position before removing the number one piston assembly straight away to safeguard the cylinder bore. Place a shop rag at least 100 mm (3.94 in.) above two wooden blocks set on the work table for light edge until the No.2 piston sub-assembly comes out. Users can repeat the same approach to disassemble the brake master cylinder kit with VSC and should first secure the master cylinder in a vise then remove the O-ring, push the piston in and use snap ring pliers to detach the snap ring. Roll a screwdriver into the piston after taping its tip to remove the straight pin by rotating the cylinder body. To protect the cylinder bore pull each No.1 and No.2 piston sub-assembly along with two springs out by hand while keeping them straight in their direction.

Inspect the master cylinder body for rust or scoring.

Place the master cylinder in a vise, remove the O-ring, push in the piston, and use snap ring pliers to remove the snap ring.

Remove the air cleaner assembly and the brake master cylinder sub-assembly by disconnecting the level warning switch connector.

Use Special Service Tool: 09023-00101.

Fill the reservoir with brake fluid, bleed the brake master cylinder and brake line, check the fluid level, inspect for leaks, and reinstall the air cleaner assembly.

Use a shop rag and 2 wooden blocks to lightly edge it out, ensuring the distance from the rag to the blocks is at least 100 mm (3.94 inches).

Fill the reservoir with brake fluid, bleed the master cylinder and brake line, install the air cleaner assembly, check the fluid level in the reservoir, and inspect for brake fluid leakage.

Apply lithium soap base glycol grease to a new O-ring and install it on the master cylinder.