OEM 2003 Toyota Corolla Brake Master Cylinder

2003 Toyota Corolla Parts Questions & Experts Answers

• Q: How to overhaul the brake master cylinder on 2003 Toyota Corolla?

  A: The first step to overhaul the brake master cylinder includes draining the brake fluid followed by immediate cleaning of paint surfaces where fluid spills occur. The first step is to remove the sub-assembly of the air cleaner cap followed by disconnecting the break fluid level switch connector from the master cylinder reservoir sub-assembly. The clutch reservoir tube No.1 requires users to slide the manual transmission clip from the master cylinder reservoir sub-assembly connection. Special Service Tool: 09023-00100 can help disconnect the two brake tubes from the master cylinder and the two or three brake tubes from the No.1 way before removing the two nuts to extract the master cylinder vacuum check valve bracket assembly. Drain the brake master cylinder reservoir sub-assembly by removing its reservoir stopper screw and its two cylinder reservoir grommets. After that, proceed with the removal process. A vise holding the master cylinder between two aluminum plates allows work while removing the O-ring and inserting the piston after removing the snap ring using snap ring pliers. To proceed further insert the piston so you can discard the piston stopper bolt and gasket while drawing out the complete No.1 piston sub-assembly in a straight configuration to shield the cylinder bore from damage. Use a work table to arrange the cloth together with two wooden blocks keeping the distance between the top of the blocks and the cloth surface at 100 mm (3.94 inches). Tap gently until the piston sub-assembly of No.2 drops out. A thorough examination of the bore takes place before adding lithium soap base glycol grease to No.1 and No.2 piston sub-assemblies that will later be properly inserted into the master cylinder without an angular alignment. Use the piston to insert the new gasket along with the piston stopper bolt while torquing to 10 Nm (102 kgf-cm, 7 ft. lbs.). After installing the snap ring proceed with the installation. Lithium soap base glycol grease should be applied to a new O-ring before mounting it to the master cylinder. Install the master cylinder reservoir with its screw after applying grease to both grommets while torquing to 1.8 Nm (18.4 kgf-cm, 15.9 inch lbs.). The flat surfaced tip of Special Service Tool: 09737-00012 pin must receive a chalk application before setting it on the master cylinder until it barely touches the piston. Applyoise Service Tool: 09737-00020 to modify the push rod length before placing it upside down on the brake booster to check the clearance. Screw in the master cylinder followed by the No.1 way and vacuum check valve bracket with two nuts using 12.5 Nm (127 kgf-cm, 9 ft. lbs.) torque, after which attach the two or three brake tubes to the No.1 way and join the two brake tubes to the master cylinder using Special Service Tool: 09023-00100 and torque them at 15.2 Nm (155 kgf-cm, 11 ft. lbs.). During manual transmission repairs you should reconnect the clutch reservoir tube No.1 with the clip to the master cylinder reservoir sub-assembly and connect the brake fluid level switch connector. Installation of the air cleaner cap sub-assembly will complete the process while you fill the reservoir with brake fluid and use Special Service Tool: 09023-00100 to bleed the master cylinder and brake line followed by checking the fluid level and examining for any brake fluid leakage.