OEM 2004 Toyota Tacoma Brake Master Cylinder

2004 Toyota Tacoma Parts Questions & Experts Answers

• Q: How to service and repair the brake master cylinder on 2004 Toyota Tacoma?

  A: The repair process for the brake master cylinder starts with first disconnecting the level warning switch connector together with the wire harness from its bracket position. Pump brake fluid through a syringe which should prevent the fluid from touching painted areas. Use Special Service Tool: 09023-00100 to disconnect three brake lines before removing the brake line from the master cylinder and 3-way by tightening it to 15 Nm (155 kgf-cm, 11 ft. lbs.). The maintenance process starts with removing the master cylinder by unscrewing its two nuts and wire harness bracket and 3-way and check valve bracket then removing the master cylinder with 13 Nm (130 kgf-cm, 9 ft. lbs.) torque. First remove the set screw and pull out the reservoir while applying 1.5 Nm (15 kgf-cm, 13 inch lbs.) torque then remove the cap with strainer. Set the cylinder inside a vise after you remove its two grommets. A screwdriver allows users to fully push pistons before removing the piston stopper bolt and gasket with 8.0 Nm (80 kgf-cm, 69 inch lbs.) torque. Remove the two pistons and springs through piston insertion using a screwdriver and snap ring removal with pliers until the No. 1 piston can be extracted away from the cylinder bore without damaging it. The removal process for No. 2 piston and spring requires the work table setup of a rag together with two wooden blocks. Tapping the cylinder flange against block edges should be performed gently to let the components drop out. Maintain a 100 mm (3.94 inch) distance between the top blocks and the rag. Check for rust and scoring on the bore of the cylinder while also looking for signs of wear or damage. Replacing or cleaning the cylinder when required. The reassembly requires the opposite sequence of disassembly steps with the application of lithium soap base glycol grease to specified rubber components. The brake booster push rod length should be adjusted before installation then brake fluid needs to be added into the reservoir followed by bleeding the brake system and leak checking before brake pedal adjustment.