OEM 2005 Toyota Highlander Brake Master Cylinder

2005 Toyota Highlander Parts Questions & Experts Answers

• Q: How to replace the Brake Master Cylinder on 2005 Toyota Highlander?

  A: The first step to replace the Brake Master w/Plate Cylinder Sub-Assembly entails removing the front suspension brace sub-assembly upper center through the elimination of its 4 nuts. During replacement of the Brake Master w/Plate Cylinder Sub-Assembly users must eliminate the air cleaner assembly for 2AZ-FE engines whereas they need to remove the air cleaner cap sub-assembly along with the air cleaner filter element sub-assembly and the air cleaner case for 3MZ-FE engines. Transfer the brake fluid from the system after drainage but wash off all paint-contacted fluid. You must utilize Special Service Tool: 09023-00100 to disconnect the 2 brake tubes from the brake master w/plate cylinder sub-assembly before removing the 2 nuts that enable the check valve bracket and the brake master/plate cylinder assembly to be pulled out. Also disconnect the brake fluid level warning switch connector at this stage. Without vacuum present inspect the brake booster push rod clearance by using an accessory tool to apply chalk on the tip against the brake booster assembly while measuring the distance which should equal 0 mm (0 in.). The specified clearance can be adjusted using Special Service Tool: 09737-00020 to fix the push rod while adjusting the protruding adjusting bolt according to the brake pedal position. The brake master w/plate cylinder sub-assembly goes in along with the check valve bracket while using 2 nuts that receive 13 Nm (130 kgf-cm, 9 ft-lbf) torque before attaching the 2 brake tubes by means of Special Service Tool: 09023-00100 to reach 15 Nm (155 kgf-cm, 11 ft-lbf) torque and finally reestablishing the brake fluid level warning switch connector. Follow these steps to fill the reservoir with brake fluid while performing necessary bleeds through Special Service Tool: 09023-00100 first on the master cylinder then the brake line and finally the brake actuator assembly. Install the air cleaner assembly for 2AZ-FE engine types and air cleaner case followed by air cleaner filter element sub-assembly and air cleaner cap sub-assembly for 3MZ-FE engine types into their respective places after checking the fluid level in the reservoir. The front suspension brace sub-assembly upper center needs installation with its 4 nuts while torqueing to 80 Nm (816 kgf-cm, 59 ft-lbf) during which the technician should check for brake fluid leakage and measure the reservoir's fluid level.