OEM 2004 Toyota Highlander Brake Booster

2004 Toyota Highlander Parts Questions & Experts Answers

• Q: How to replace the vacuum brake booster on 2004 Toyota Highlander?

  A: The vacuum brake booster replacement starts by taking out the front suspension brace sub-assy upper center and the air cleaner assy (2AZ-FE), air cleaner cap sub-assy (3MZ-FE), air cleaner filter element sub-assy (3MZ-FE), and air cleaner case (3MZ-FE). The brake fluid draining process requires cleaning away the paint residue from touched regions. Special Service Tool 09023-00100 helps users disconnect the brake master w/plate cylinder sub-assy before proceeding to remove the instrument panel finish panel sub-assy lower and brake pedal return spring. Detach the brake master cylinder push rod clevis by removing its clip together with the push rod pin followed by unlocking the push rod lock nut. First unclip both claw fittings of the clamp to disconnect the two brake tubes from the body. Then carefully pull the tubes apart. Take out the brake booster assy by first disconnecting the vacuum hose from the check valve assy and then sliding the clip followed by unscrewing the 4 nuts so as to safely extract the brake booster assy under which the brake tubes and wire harness must be protected from damage. After removing the brake booster gasket together with the brake vacuum check valve assembly install the grommet followed by the check valve assembly onto the brake booster assembly before applying a new brake booster gasket. The brake booster requires reinstallation using 4 nuts tightened to 13 Nm (130 kgf-cm, 9 ft. lbs.) while connecting the vacuum hose with its clip positioned correctly. Each brake tube clearing should be installed onto the body without causing damage to brake tube components. The brake master cylinder push rod clevis requires install of the lock nut followed by torquing to 26 Nm (265 kgf-cm and 19 ft. lbs.). Apply lithium soap base glycol grease to the clevis pin before adding the push rod pin and clip. After putting in place the brake pedal return spring you should adjust the brake booster push rod by utilizing Special Service Tools 09023-00100, 09737-00020, 09737-00012. Install the brake master w/plate cylinder sub-assy while filling the reservoir with brake fluid and performing a master cylinder bleed operation as well as brake line bleeding using Special Service Tool: 09023-00100. Inspection of brake fluid leakage should be followed by measuring reservoir fluid level and performing brake pedal height adjustment. The procedure ends with installation of the instrument panel finish panel sub-assy lower followed by air cleaner assy (2AZ-FE), air cleaner case (3MZ-FE), air cleaner filter element sub-assy (3MZ-FE), air cleaner cap sub-assy (3MZ-FE), and the front suspension brace sub-assy upper center.