OEM 2002 Toyota Highlander Brake Master Cylinder Reservoir

2002 Toyota Highlander Brake Master Cylinder Reservoir Parts Q&A

• Q: How to replace the Brake Master Cylinder Reservoir Sub-Assembly on 2002 Toyota Highlander?

  A: The first step to change the Brake Master Less Reservoir Tank Cylinder Sub-Assembly includes draining brake fluid while taking care it does not contact painted surfaces. Begin by removing the air cleaner assembly with hose and proceed to detach the front suspension brace sub-assy upper center through wire harness clamp and ABS R/B disconnection when needed followed by unfastening the four nuts on the brace. The brake fluid level warning switch connector needs removal along with potential actuator No. 1 hose detaching from the reservoir by sliding a clip. Use Special Service Tool: 09023-00100 to remove the 2 brake lines before taking out the check valve bracket and master cylinder sub-assy by removing its 2 nuts. You should also remove the brake master cylinder gasket and the reservoir tank stopper before pulling out the master cylinder reservoir sub-assy and removing the 2 grommets. Lithium soap base glycol grease should be applied to the new grommets before they are installed in the master cylinder reservoir sub-assy, followed by the complete assembly placement to the master cylinder. The reservoir tank stopper should be installed with proper fitment before applying a new gasket. When replacing the master cylinder use the accessory tool which requires chalk, place it against the brake booster to measure the push rod clearance and adjust using Special Service Tool: 09737-00020. Lock the master cylinder sub-assy and check valve bracket into place using 2 nuts that should be torqued up to 13 Nm (130 kgf-cm, 9 ft. lbs.). Then use Special Service Tool: 09023-00100 to torque the 2 brake lines to 15 Nm (155 kgf-cm, 11 ft. lbs.). The job requires reconnection of the actuator No. 1 hose followed by attaching the brake fluid level warning switch connector. Reinstall the front suspension brace sub-assy upper center using 4 nuts while torquing them to 80 Nm (815 kgf-cm, 59 ft. lbs.). Also reconnect wire harness clamps where needed. Reinstall the air filter system while attaching the hose before filling the brake fluid reservoir and bleeding master cylinder lines and brake tube. The procedure ends with checking the fluid level and inspecting the system for any fluid leakage.