OEM 2003 Toyota Highlander Brake Booster

2003 Toyota Highlander Parts Questions & Experts Answers

• Q: How to replace the Vacuum Brake Booster on 2003 Toyota Highlander?

  A: Before commencing with the replacement of the Vacuum Brake Booster begin by draining brake fluid to avoid paint surface contamination. The air cleaner assembly with hose requires removal before disconnecting either one wire harness clamp (VSC not present) or two wire harness clamps and ABS R/B components (VSC present). Afterwards detach four nuts for installation. Begin by pulling out the brake master less reservoir tank cylinder sub-assy along with removing the brake master cylinder gasket and brake actuator assy (without VSC) or the ABS & traction actuator assy (with VSC). The tool sequence requires workers to first remove the instrument panel finish panel sub-assy lower and instrument panel insert sub-assy lower left-hand side. Then the brake pedal return spring and push rod pin must be eliminated. Following these steps, workers should remove the brake booster assy after taking out two nuts, disconnecting brake lines from the body and sliding a clip to break vacuum hose linkage before removing four nuts and clevis for installation. Place the new brake booster gasket and proceed with installing it after taking the brake booster assy out. The installation procedure includes clamping the clevis onto the booster push rod, tightening four nuts to 13 Nm specifications and securing both brake lines to the body with 5.0 Nm torque values then restoring vacuum hose connection with the clip. The push rod pin together with the brake pedal return spring should be installed first along with the instrument panel insert sub-assy lower left-hand side and the instrument panel finish panel sub-assy lower. First, install the brake actuator assembly (for cars without VSC) or ABS & traction actuator assembly (for cars with VSC) followed by application of a new brake master cylinder gasket before master less reservoir tank cylinder sub-assy installation. After installing the four nuts on the front suspension brace sub-assy upper center with 80 Nm torque value proceed with reattaching the wire harness clamp (VSC models without this component) or the ABS R/B and two wire harness clamps (VSC models with these components). Installation of the air cleaner assembly with hose requires filling the reservoir with brake fluid followed by bleeding the master cylinder and brake line then checking the fluid level and inspecting for leakage and adjusting the brake pedal height.