OEM 2004 Toyota RAV4 Brake Booster

2004 Toyota RAV4 Parts Questions & Experts Answers

• Q: How to service and repair the vacuum brake booster on 2004 Toyota RAV4?

  A: Service and repair of the vacuum brake booster starts with master cylinder removal then vacuum hose unhooking from the brake booster followed by the disconnecting of pedal return spring and clip and clevis pin removal before pulling out the brake booster using a four-nut and clevis process along with brake booster and gasket extraction. New gaskets and boosters must be installed while the operating rod gets its clevis attached before torquing all booster installation nuts to 13 Nm (130 kgf-cm, 9 ft. lbs.). Hook the clevis pin through clevis then brake pedal followed by clipping it before putting back the pedal return spring. The booster push rod length needs adjustment by installing a new gasket on the master cylinder then setting Special Service Tool: 09737-00011 on the gasket while lowering the pin until it reaches the piston lightly. Apply Special Service Tool: 09737-00020 to lengthen the push rod until it makes light contact with the pin head while the brake pedal is depressed enough for extension. Check that the booster push rod clearance with the pin head measurement equals 0 mm (0 in.). After installing the master cylinder and filling the brake reservoir with fluid you need to connect the vacuum hose to the brake booster and run the brake system bleed process. First check for leaks before adjusting the brake pedal while tightening the clevis lock nut to 26 Nm (260 kgf-cm, 20 ft. lbs.). Then perform an operational check.