OEM 2005 Toyota Highlander Brake Booster

2005 Toyota Highlander Parts Questions & Experts Answers

• Q: How to replace the Vacuum Brake Booster on 2005 Toyota Highlander?

  A: The replacement process for the Vacuum Brake Booster begins with first removing the front suspension brace sub-assembly upper center followed by removal of the air cleaner assembly (2AZ-FE) and then the air cleaner cap sub-assembly (3MZ-FE) before proceeding with the air cleaner filter element sub-assembly (3MZ-FE) and concluding with the air cleaner case (3MZ-FE). Flush out brake fluid before washing the paint since the fluid sticks to surfaces. Use Special Service Tool 09023-00100 to detach the brake master w/plate cylinder sub-assembly followed by removal of the instrument panel finish panel sub-assembly lower and the brake pedal return spring. Unscrew the clevis from the brake master cylinder push rod by beginning with removing the push rod pin along with the clip and then loosening the lock nut and taking out the clevis. Release the 2 claw fittings of the clamp to separately extract the 2 brake tubes from the body with extreme care. Slipping the clip before disconnecting the vacuum hose from the check valve assembly allows you to remove the 4 brake booster assembly nuts with care for the brake tubes and wire harness. After removing the brake booster gasket along with the brake vacuum check valve assembly install the grommet and check valve component onto the brake booster assembly before putting on a fresh brake booster gasket. The brake booster assembly installation requires 4 nuts tightened to 13 Nm (130 kgf-cm, 9 ft. lbs.) then the vacuum hose should be connected while the clip is returned to its position. Line up the brake tube so its two clearings fit correctly against both body sections yet avoid any brake damage. The brake master cylinder push rod clevis must be installed along with its lock nut by tightening to 26 Nm (265 kgf-cm, 19 ft. lbs.) while applying lithium soap base glycol grease to the clevis pin followed by securing it with the push rod pin and clip. Reinstall the brake pedal return spring followed by inspecting and readjusting the brake booster push rod through Special Service Tools 09023-00100 and 09737-00020 and 09737-00012. The installation process of the brake master w/plate cylinder sub-assembly requires filling brake fluid into the reservoir followed by bleeding functions with Special Service Tool: 09023-00100 to remove air from the system. After brake fluid leakage inspection and brake fluid level checks, the brake pedal height should be inspected and adjusted. To complete the installation finish the lower panel of the instrument panel and reinstall both the 2AZ-FE air cleaner assembly and 3MZ-FE air cleaner assembly and its case and filter element and cap sub-assemblies and upper center bracket of the front suspension brace.