OEM 2003 Toyota RAV4 Brake Booster

2003 Toyota RAV4 Parts Questions & Experts Answers

• Q: How to service and repair the vacuum brake booster on 2003 Toyota RAV4?

  A: Starting vacuum brake booster service requires you to detach the master cylinder followed by vacuum hose removal from the brake booster and removing the pedal return spring and clip and clevis pin before extracting the brake booster through clevis removal followed by four nuts then pulling out the brake booster with its gasket. Begin installation by first installing new gasket materials along with boosters then connect the clevis to the operating rod and torque booster installation nuts to 13 Nm (130 kgf-cm, 9 ft. lbs.). Begin by placing the clevis pin inside the clevis and brake pedal then secure it with the clip and finally mount the pedal return spring. Push rod length adjustment is possible with two new master cylinder gaskets and use of Special Service Tool: 09737-00011 which should reach the piston through gasket deformations when the pin touches it. Place Special Service Tool 09737-00011 right side up on the booster and measure the space between the booter push rod and pin head to confirm a 0 mm (0 inch) distance. The booster push rod length adjustment should be completed with Special Service Tool: 09737-00020 until the rod makes light contact with the pin head while depressing the brake pedal sufficiently for rod extension. Bleeding of the brake system follows after installation of the master cylinder and connecting the vacuum hose and brake reservoir filling with brake fluid. The technician should first check for leaks followed by braking pedal adjustment then tighten the clevis lock nut to 26 Nm (260 kgf-cm, 20 ft. lbs.) prior to performing the operational check.