Toyota 89540-60430
Control Module

The first step to separate the antilock brake hydraulic control assembly starts with installing the hydraulic brake booster into a vise that requires Special Service Tools including 09630-00014 (09631-00142) and 09950-60010 (09951-00180, 09951-00190). Use a locking plier to disconnect the fluid warning switch while you remove its bolt and clamp. Start by removing the reservoir cap before exploring the reservoir through 3 set screw unthreading at 1.7 Nm torque (17.5 kgf-cm, 15.2 inch lbs.) while you also remove the 3 grommets. The technician should first loose the lock nut to detach the clevis and lock nut by applying 25 Nm of torque (260 kgf-cm, 19 ft. lbs.) before removing the cylinder boot. Make use of Special Service Tool: 09023-00101 to gently extract brake actuator tube No. 1 at 15 Nm (155 kgf-cm, 11 ft. lbs.). Before you begin disassembling the booster pump and assembly start by unfastening the actuator hose then take away all 4 screws and wire harness before proceeding with 2 accumulator bracket bolts, two booster pump motor assembly bolts, the bolt from the No.1 pump bracket along with two washers, 2 cushions, 2 collars and sleeve until you finally remove the 2 No. 2 pump bracket bolts and cushion. A torque of 81 Nm (830 kgf-cm, 60 ft. lbs.) with assistance of a 30 mm deeper socket wrench removes the master cylinder pressure sensor, following requirements to use part No: 89637-30050 as replacement. The piston removal process begins with pushing the screwdriver against it to depress the component while using a pin to expel the snap ring followed by pulling the piston directly out to prevent harm to the cylinder bore. Apply Special Service Tool: 09318-12010 to remove the accelerator from the booster pump under a torque of 54 Nm (550 kgf-cm, 36 ft. lbs.) prior to removing the silencer tube and its components as well as the O-ring. The hydraulic brake booster pump motor function must be tested after connecting the battery leads to each pump motor terminal. Set the accumulator inside a vise after covering it with a cloth before cutting the body with a saw only near the specified stretch length to achieve safe gas ventilation. The reverse process of disassembly should be followed for reassembly while the accumulator bracket requires fitting according to specific clearances where measurements A + B should equal 4.1 mm (0.161 inch) or less and C should range between 0.3 - 3.8 mm (0.012 - 0.150 inch) with a necessary 0.3 mm (0.012 inch) gap for both A and B.

Use Special Service Tool: 09318-12010 to remove the accumulator from the booster pump with a torque of 54 Nm (550 kgf-cm, 36 ft. lbs.), and then remove the silencer tube, spring, and O-ring.