OEM 2002 Toyota Highlander Brake Booster

2002 Toyota Highlander Parts Questions & Experts Answers

• Q: How to replace the Vacuum Brake Booster on 2002 Toyota Highlander?

  A: The first procedure for replacing the Vacuum Brake Booster requires drainage of brake fluid which must not stay on painted surfaces. Start by disconnecting the wire harness clamp for non-VSC models before you remove the four nuts holding the brace sub-assy in place and then proceed to detach the upper center sub-assy. VSC-equipped models need the removal of wire harness clamps and the ABS R/B before removing the sub-assy nuts. The process begins with the removal of the brake master less reservoir tank cylinder sub-assy by using Special Service Tool: 09023-00100 followed by the brake master cylinder gasket extraction. For models without VSC, remove the brake actuator assy using the same special service tool, and for models with VSC, remove the ABS & traction actuator assy. Proceed to remove the instrument panel finish panel sub-assy lower and the instrument panel insert sub-assy lower left-hand side, then take out the brake pedal return spring and push rod pin before removing the brake booster assy by taking off the two nuts, separating the brake lines from the body, disconnecting the vacuum hose, and removing the four nuts and clevis. Remove the brake booster gasket from its position then install a new one for replacement. The clevis should be bolted to the booster push rod before installation following four nut attachment with torque values set to 13 Nm. Then the brake lines connect to the body with two nuts reaching a torque of 5.0 Nm. Finally install the vacuum hose with its clip before resuming service. Safety begins with reattaching the push rod pin along with the brake pedal return spring before installing the instrument panel insert sub-assy lower left-hand side and instrument panel finish panel sub-assy lower. The new brake master cylinder gasket gets installed first before putting back the brake master less reservoir tank cylinder sub-assy using Special Service Tool: 09023-00100 on both models without VSC and models with VSC. The front suspension brace sub-assy upper center requires four nuts tightened to 80 Nm while reconnecting the wire harness clamp for models without VSC and the ABS R/B and two wire harness clamps for models with VSC before installing the air cleaner assembly with hose. The brake fluid filling process must be followed by a master cylinder bleed through Special Service Tool: 09023-00100 after which you should bleed the brake line and verify the fluid level then inspect for brake fluid leakage before checking and adjusting the brake pedal height.