OEM 2004 Toyota Highlander Brake Master Cylinder

2004 Toyota Highlander Parts Questions & Experts Answers

• Q: How to replace the Brake Master Cylinder with Plate Cylinder Sub-Assembly on 2004 Toyota Highlander?

  A: One must start the replacement procedure of Brake Master Cylinder with Plate Cylinder Sub-Assembly by dismantling the front suspension brace sub-assy upper center through 4 nut removal. The air cleaner assembly must be removed for vehicles with a 2AZ-FE engine and operators with a 3MZ-FE engine need to take off the air cleaner cap sub-assy together with the air cleaner filter element sub-assy and air cleaner case. You must drain the brake fluid and thoroughly wash paint areas affected by residue. Special Service Tool: 09023-00100 helps users disconnect the 2 brake tubes from the brake master w/plate cylinder sub-assy before they remove the 2 nuts that hold the check valve bracket and brake master w/plate cylinder assembly. When performing a brake booster push rod adjustment without vacuum, position an accessory tool against the assembly to apply chalk then measure the clearance that should be precisely 0 mm (0 in.). Special Service Tool: 09737-00020 allows fixing the push rod with the necessary adjustments by changing the protruding adjusting bolt length when the brake pedal remains adequately depressed. The brake master w/plate cylinder sub-assy together with check valve bracket receive 2 nuts that get tightened to 13 Nm (130 kgf-cm, 9 ft-lbf) before attaching the 2 brake tubes with Special Service Tool: 09023-00100 while torquing to 15 Nm (155 kgf-cm, 11 ft-lbf) and reconnecting the brake fluid level warning switch connector. Refill the brake fluid reservoir before completing an assisted bleed of the master cylinder with Special Service Tool: 09023-00100. Proceed to bleed the brake line and finish with the brake actuator assembly bleed. Before proceeding install the air cleaner assembly first and then the air cleaner case and finally the air cleaner filter element sub-assy and air cleaner cap sub-assy according to the 3MZ-FE engine type requirements. The last step involves reinstallation of the front suspension brace sub-assy upper center using 4 nuts which require a torque of 80 Nm (816 kgf-cm, 59 ft-lbf) before inspecting brake fluid leakage and reservoir fluid level.