Toyota 47207-0C010
Master Cylinder

Service and repair of the Double Cab brake master cylinder starts with disconnecting the level warning switch connector while keeping the brake booster push rod unadjusted along with the diameter converting unit and brake combination intact. A syringe should be used to remove fluid while keeping painted surfaces clear of brake fluids. Remove the master cylinder and 3-way release their connected brake lines with Special Service Tool: 09023-00100 following a torque specification of 15 Nm (155 kgf-cm, 11 ft. lbs.) and eliminate the two nuts securing the master cylinder. Start by removing the brake master cylinder reservoir tank stopper before pulling down the reservoir and unscrewing the cap with strainer inside. You should place the brake master cylinder into a vise with aluminum plates featuring soft jaws and use a screwdriver to discard the O-ring. Special Service Tool: 09023-00100 enables brake tube detachment from the brake master cylinder before removing the two nuts then two bolts and finally the brake master cylinder sub-assembly. Do not allow the No. 3 piston from the diameter converting unit and the No. 1 piston from the plunger master cylinder to fall as they become unreusable after hitting the ground. By using a screwdriver remove the two O-rings from the system and use a 5 mm pin punch and hammer to extract the pin before taking out the brake master cylinder union and its accompanying two brake master cylinder union grommets. Examine the cylinder bore for rust damage as well as scoring then inspect it for wear and damage before cleaning or replacing the cylinder if needed. After disassembly completion reinstall the parts starting with the reverse order while applying lithium soap base glycol grease to the rubber components as indicated. The fixture of this component begins by running through the removal procedure in reverse order while adjusting the brake booster push rod length before you fill the reservoir with brake fluid and bleed the brake system. After finishing these steps you should check for leaks and adjust the brake pedal height and verify the brake actuator using the TOYOTA hand-held tester.

Remove the 2 nuts, wire harness bracket, 3-way, and check valve bracket with a torque of 13 Nm (130 kgf-cm, 9 ft. lbs.), then pull the master cylinder from the brake booster.

Use Special Service Tool: 09023-00101 to detach the 5 brake lines from the master cylinder and 3-way.