OEM 2004 Toyota Solara Brake Booster

2004 Toyota Solara Parts Questions & Experts Answers

• Q: How to replace the brake booster assembly on 2004 Toyota Solara?

  A: Draining brake fluid remains the first step before replacement of the brake booster assembly but you need to wash off any fluid which contacts painted surfaces. Use Special Service Tool: 09023-00100 to detach both the air cleaner assembly alongside the brake master cylinder sub-assembly. The brake booster assembly requires removal of the vacuum hose assembly clip before taking out the hose from the brake booster assembly. The installation process begins with Special Service Tool: 09023-00100 used to remove the front brake tube No.5 before continuing to take off the front door scuff plate LH and cowl side trim sub-assembly LH as well as instrument panel finish lower panel LH. To remove the brake pedal return spring and the push rod pin you need to unlock its connecting clip. The brake master cylinder push rod clevis requires removal after you loosen its lock nut. Proceed to separate the brake booster assembly by unbolt its 4 nuts then extract it slowly to maintain integrity of brake tubes and wire harness. Use new brake booster gasket to replace the previous one. Install the brake booster assembly using its 4 nuts while applying torques at 13 Nm (130 kgf-cm, 9 ft. lbs.) but maintain constant attention to brake tubes and wire harness safety. After aligning the brake pedal height the tech installs the push rod clevis with its lock nut but torques the nut only after completion. Apply lithium soap base glycol grease first to the designated area before you install both the push rod pin and clip combined with the brake pedal return spring. The service technician needs to reattach the instrument panel finish lower panel LH followed by cowl side trim sub-assembly LH and front door scuff plate LH. After installing the front brake tube No.5 with Special Service Tool: 09023-00100, torque it to 15 Nm (155 kgf-cm, 11 ft. lbs.) before connecting the vacuum hose assembly by sliding the clip into place. The brake booster push rod adjustment must be inspected along with using Special Service Tool: 09023-00100, 09737-00013, 09737-00020 before installing the brake master cylinder sub-assembly. After filling the brake fluid into the reservoir technicians must use Special Service Tool: 09023-00100 to bleed the master cylinder followed by the brake line. They should then reinstall the air cleaner assembly before checking the fluid level and inspecting for leakage after adjusting the brake pedal height.