OEM 2003 Toyota MR2 Spyder Brake Booster

2003 Toyota MR2 Spyder Parts Questions & Experts Answers

• Q: How to service and repair the vacuum brake booster on 2003 Toyota MR2 Spyder?

  A: The service and repair process for the vacuum brake booster starts with master cylinder and tool box removal followed by vacuum hose detachment from the brake booster and subsequent removal of the 2 brake lines using Special Service Tool: 09023-00100 to detach them from the ABS actuator. Start by removing the brake booster through a process that first requires needle-nose pliers to detach the return spring and clip followed by clevis pin and wave washer then finish with removing 4 nuts and clevis before pulling out the brake booster and gasket. The new brake booster installation requires insertion of the brake booster and gasket followed by nut torquing to 13 Nm (130 kgf-cm 9ft. lb.). Afterwards, attach the clevis to the brake pedal by installing the wave washer and clevis pin and clip before reinstalling the pedal return spring with needle-nose pliers. Special Service Tool: 09737-00011 enables mastering cylinder pin adjustment until the piston receives a gentle touch. The technician then flips the tool to position it on the booster for measuring the booster push rod clearance against the pin head. The technician achieves perfect alignment when the measurement reads 0 mm (0 inch). The process ends with Special Service Tool: 09737-00020 providing the necessary length adjustment to achieve this desired contact. The installation of the brake booster vacuum hose should be followed by attaching the 2 brake lines to the ABS actuator which requires a torque of 15 Nm (155 kgf-cm, 11 ft. lbs.) for 1 line and 14 Nm (143 kgf-cm, 10 ft. lbs.) for the other line using a torque wrench set to 30 cm (11.81 inch) fulcrum length. After reinstalling the master cylinder you should fill the reservoir with brake fluid and perform brake system bleeding and inspect for any fluid leakage and check and adjust the brake pedal followed by an operational test before replacing the tool box and luggage compartment trim box cover.