OEM 2004 Toyota Solara Brake Master Cylinder

2004 Toyota Solara Parts Questions & Experts Answers

• Q: How to overhaul the brake master cylinder sub-assembly on 2004 Toyota Solara?

  A: The beginning stage of brake master cylinder subassembly overhaul requires draining brake fluid together with proper cleaning of remaining fluid from painted surfaces. Separated components start with removing the air cleaner assembly followed by disconnecting the level warning switch connector. Special Service Tool: 09023-00100 enables workers to disconnect the 6 brake tubes from the master cylinder while removing the two nuts to slide out the 2-way and brake master cylinder sub-assembly. The brake master cylinder reservoir filler cap assembly and reservoir strainer need removal first while proceeding to remove the reservoir sub-assembly with the screw. The technician should first take out the two master cylinder reservoir grommets from the system before proceeding with the brake master cylinder removal process. They should place the master cylinder into the vise to remove the o-ring and piston snap ring with snap ring pliers. Push the piston once more to evacuate the piston stopper bolt along with its gasket before retrieving the No. 1 piston sub-assembly straight out from the cylinder bore without causing damage. To remove the No. 2 piston sub-assembly use a shop rag together with two wooden blocks while lightly edging it out until it drops free while keeping the rag at 100 mm (3.94 inches) distance from the blocks' tops. During brake master cylinder kit with VSC assembly the straight pin needs removal when the piston is pushed with a screwdriver. Before putting on the brake master cylinder kit without VSC you should first check the master cylinder body for any trace of rust or scoring. Then apply lithium soap base glycol grease to the new No. 1 and No. 2 piston sub-assemblies before inserting them with care to protect the rubber lips and adding a new gasket and piston stopper bolt with 10 Nm (100 kgf-cm, 7 ft. lbs.) torque. With VSC included kit, position the groove of No. 2 piston horizontally when inserting it before installing the straight pin and snap ring. After oiling a new O-ring users must place it into the master cylinder. Proceed with the installation of grommets for the master cylinder reservoir before fitting the reservoir component with screw attachment and strainer assembly then fill cap assembly. The inspection procedure requires Special Service Tool: 09737-00013 for brake booster push rod clearance measurement which must be set at 0 mm (0 inch). You should utilize Special Service Tool: 09737-00020 for adjusting the length of the protruding adjusting bolt after fixing the push rod. Install the master cylinder sub-assembly while securing 2 nuts before connecting 6 brake tubes by using Special Service Tool: 09023-00100 and restoring the level warning switch connector. Add brake fluid into the reservoir while performing a bleed of the master cylinder along with the brake line before you install the air cleaner assembly and verify the fluid level then check for any brake fluid leaks.