Toyota 47220-08030
Master Cylinder Reservoir

The service and repair process for Brake Master Less Reservoir Tank Cylinder Sub-Assembly starts with fluid drainage from braking systems followed by cleaning paint surfaces exposed to drained fluid. First disconnect the battery negative terminal followed by removal of the air cleaner assembly with hose and the cowl top panel sub-assembly outer front. It will then become necessary to disconnect the brake master cylinder using Special Service Tool: 09023-00100. The tool enables you to disconnect both brake tubes while sliding the clip to detach the reservoir hose and removing the two nuts. To access the brake master less reservoir tank cylinder sub-assembly securely position the brake master cylinder between soft-jawed vise and aluminum plates before removing the O-ring with a screwdriver. The brake tube requires Special Service Tool: 09023-00100 to disconnect for further detachment of two nuts and two bolts while removing the sub-assembly from its position. Drop the No.3 piston from the diameter converting unit and the No.1 piston from the plunger master cylinder because replacement parts cannot be used if these components fall. A pin punch of 5 mm diameter together with a hammer should be used to remove the pin before taking out the brake master cylinder union and two grommets. For brake master less reservoir tank cylinder sub-assembly installation you should apply lithium soap base glycol grease to the grommets then insert the master cylinder union with the pin while adding the two new O-rings. Fasten the sub-assembly with two nuts and two bolts while torquing them to 25 Nm (255 kgf-cm, 18 ft. lbs.) then check for proper installation of the No.3 piston without looseness. After connecting the brake tube to the brake master cylinder using Special Service Tool: 09023-00100 and torquing it to 15 Nm (155 kgf-cm, 11 ft. lbs.) install a new O-ring before continuing. Reinstall the brake master cylinder with two nuts and torques them to 13 Nm (130 kgf-cm, 9 ft. lbs.) but before doing so reconnect the reservoir hose then use Special Service Tool: 09023-00100 to restore connection of the two brake tubes which demands a torque of 15 Nm (155 kgf-cm, 11 ft. lbs.). Proceed with the following brake system installation steps by filling the reservoir with brake fluid, bleeding both the master cylinder and brake line followed by checking reservoir fluid level, examining for leakage, reattaching the cowl top panel front outer and inspecting brake pedal height. Finish by testing the brake actuator with a Toyota hand-held tester.

The first step for Brake Master Less Reservoir Tank Cylinder Sub-Assembly service requires draining brake fluid before cleaning painted surfaces with spills. Unplug the battery as a first step before removing the air cleaner assembly with hose and the cowl top panel sub-assembly outer front. Use Special Service Tool: 09023-00101 to disconnect two brake tubes and slide the clip loose from the reservoir hose and remove the two nuts. The procedure for the brake master less reservoir tank cylinder sub-assembly requires placement of the master brake cylinder into a soft-jawed vise using aluminum plates followed by O-ring removal with a screwdriver. Follow the instructions from Special Service Tool: 09023-00101 to remove the brake tube then detach the two nuts and two bolts and sub-assembly before dropping the No.3 piston from the diameter converting unit or No.1 piston from the plunger master cylinder as these parts cannot be reused after dropping. Remove first the two O-rings then utilize a 5 mm pin punch and a hammer to remove the pin afterward under which circumstances remove the brake master cylinder union with two grommets. The installation of new sub-assembly requires first applying grease to two grommets before installation followed by pin union attachment using a pin punch and hammer and subsequent addition of two new O-rings and completion with two nuts and two bolts tightening to 25 Nm (255 kgf-cm, 18 ft. lbs.). It is essential to install the No. 3 piston with no loose space when uniting the diameter converting unit to the master cylinder. Fitting the master cylinder brake tube will take Special Service Tool: 09023-00101 before torqueing it to 15 Nm (155 kgf-cm, 11 ft. lbs.). Install the new O-ring at this time. The procedure includes reattaching the reservoir hose and using Special Service Tool: 09023-00101 to connect the two brake tubes which require 15 Nm (155 kgf-cm, 11 ft. lbs.) torque. Installation includes the air cleaner assembly with hose then filling the reservoir with brake fluid while using Special Service Tool: 09023-00101 to bleed the master cylinder followed by bleeding the brake line before checking the fluid level and inspecting for brake fluid leakage. The cowl top panel sub-assembly outer front should be reinstalled next before inspecting brake pedal height and checking the brake actuator using the Toyota hand-held tester.