OEM 2002 Toyota MR2 Spyder Brake Booster

2002 Toyota MR2 Spyder Brake Booster Parts Q&A

• Q: How to service and repair the vacuum brake booster on 2002 Toyota MR2 Spyder?

  A: The service and repair of the vacuum brake booster begins with master cylinder and tool box removal before vacuum hose disconnection from the brake booster and 2 brake lines removal through the use of Special Service Tool: 09023-00100 to detach them from the ABS actuator. Start by detaching the brake booster through the following sequence: first use needle-nose pliers to take off the return spring and clip then the clevis pin and wave washer before you can complete the removal with 4 nuts and clevis leading to the brake booster coming out along with its gasket. To perform the installation replace the brake booster by setting it on new gaskets while tightening the 4 nuts to 13 Nm (130 kgf-cm, 9 ft. lbs.). Afterward, connect the clevis to the brake pedal through installation of the wave washer together with the clevis pin and clip before reinstalling the pedal return spring with needle-nose pliers. To replace only the brake master cylinder technicians must operate Special Service Tool number 09737-00011 on the master cylinder and allow the pin to rest at the piston with minimal contact before flipping the tool upside down to position it on the booster for measurement of booster push rod and pinhead clearance which should be set at 0 mm (0 inch). They should use Special Service Tool: 09737-00020 to adjust the push rod length until it makes gentle contact with the pinhead. When using Special Service Tool 09737-00011 install the 2 brake lines to the ABS actuator by torquing them to 15 Nm (155 kgf-cm, 11 ft. lbs.) and 14 Nm (143 kgf-cm, 10 ft. lbs.) using a torque wrench with a fulcrum length of 30 cm (11.81 inch). The last procedure includes master cylinder installation followed by brake fluid reservoir filling before performing brake system bleeding. Complete the process by checking for fluid leaks and adjusting the brake pedal. Then do an operational check followed by reinstalling the tool box plus luggage compartment trim box cover.