OEM 2003 Toyota Highlander Brake Master Cylinder

2003 Toyota Highlander Parts Questions & Experts Answers

• Q: How to replace the Brake Master Cylinder Sub-Assembly on 2003 Toyota Highlander?

  A: Brake fluid removal should begin first when replacing the Brake Master Less Reservoir Tank Cylinder Sub-Assembly while avoiding the application of fluid onto painted surfaces. First disconnect the air cleaner with hose before removing the front suspension brace sub-assembly upper center by taking off wire harness clamps and ABS R/B connections depending on the model. Also remove the four nuts. Initial steps include disconnecting the brake fluid level warning switch connector then sliding the clip to detach the actuator No. 1 hose (if equipped with VSC). Special Service Tool: 09023-00100 should be used to remove the 2 brake lines. The 2 nuts need removal to extract the check valve bracket with master cylinder sub-assembly from its place. Start by removing both the brake master cylinder gasket together with the reservoir tank stopper before pulling out the master cylinder reservoir sub-assembly and taking off its 2 grommets. Cleansed grommets should be installed onto the master cylinder reservoir sub-assembly and then the same assembly should be fitted to the master cylinder after treatment with lithium soap base glycol grease. Fasten the reservoir tank stopper correctly before adding a new gasket. When changing the master cylinder use Special Service Tool: 09737-00020 to measure the clearance between push rod and accessory tool position while the tool rests against brake booster after applying chalk to its tip. Reset the tool as needed. Mount the master cylinder sub-assembly with check valve bracket by securing two nuts at 13 Nm (130 kgf-cm, 9 ft. lbs.) before using Special Service Tool: 09023-00100 to fasten the two brake lines with a torque of 15 Nm (155 kgf-cm, 11 ft. lbs.). Reattach the actuator No. 1 hose together with the brake fluid level warning switch connector. Fasten the front suspension brace sub-assembly upper center through four nuts while applying torque of 80 Nm (815 kgf-cm, 59 ft. lbs.) and handle the wire harness clamps per their specific requirements. The completion of the procedure includes brake fluid filling in the reservoir followed by bleeding the master cylinder along with the brake line and fluid level inspection of the reservoir without neglecting any signs of brake fluid leakage.