OEM 2004 Toyota Tundra Brake Booster

2004 Toyota Tundra Parts Questions & Experts Answers

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

  A: Before working on the vacuum brake booster assembly of other models except Double Cab you need to remove the master cylinder and disconnect the vacuum hose. First remove the scuff plate from the left side, the cowl side trim piece plus lower finish panel and No. 2 heater to register duct. Pop out the pedal return mechanism but keep its hardware in place to remove the brake booster by unfastening 4 nuts and clevis before slowly lifting the booster with its rubber gasket. Finally disassemble the booster by taking off the 2 stopper rings and installing hardware from the booster bracket and gasket. First put a fresh gasket in place for the brake booster and afterward install the brake booster bracket plus 2 stopper rings. Fit a new gasket onto the booster while installing this hardware. Then attach the clevis to the operating rod and tighten booster installation nuts to 13 Nm (130 kgf-cm, 9ft.lbs). Reattach the vacuum hose to the brake booster when you have joined the clevis with the clevis pin and brake pedal. Reinstall the No. 2 heater register duct while placing back the lower finish panel, cowl side trim on the left, and scuff plate. Set Special Service Tool 09737-00011 on the master cylinder until it gently touches the piston before reversing the tool to view the space between booster push rod and pin head. The intended gap is 0 mm (0 inch). You should use Special Service Tool: 09737-00020 to modify the booster push rod length until it contacts the pin head. Put back the master cylinder while adding brake fluid into the reservoir then bleed the brake system and test all components during routine maintenance.