OEM 2005 Toyota Prius Brake Master Cylinder

2005 Toyota Prius Parts Questions & Experts Answers

• Q: How to replace the brake master cylinder sub-assembly on 2005 Toyota Prius?

  A: The first step to replace the brake master cylinder sub-assembly requires wiper arm removal from both sides along with the hood to cowl top seal and ventilator louvers from left and right sides followed by the windshield wiper motor and link assembly. Switch off the brake control system (ECB) through relay removal of No.1 and No.2 to avoid air contamination of the actuator when bleeding it. The cowl top panel sub-assembly requires the removal of 2 bolts along with 3 clamps and 7 bolts from its outer front section. Start by removing the w/converter inverter component followed by draining brake fluid and finally extracting the instrument panel register assembly No.1 together with the instrument panel finish panel sub-assembly lower. To remove the brake master cylinder sub-assembly one must disconnect the brake return spring as well as unfasten the clip and push rod pin and 4 clips and 2 reservoir tube hoses and finally detach the actuator bracket bolt. The front brake tubes No.1 need removal through the special service tool 09023-00101 to break free tubes No.2 from their clamp connection with the brake master cylinder sub-assembly. Use the same special service tool to detach brake tube and 2 way while removing the brake master cylinder sub-assembly and its 2 nuts along with its gasket. Unravel the clevis lock nut to detach the push rod clevis. Before installing the push rod clevis to the brake master cylinder sub-assembly users must secure the lock nut and apply lithium soap base glycol grease to new grommets that require a screw for mounting then torque the screw to 1.8 Nm (18 kgf-cm, 16 inch lbs.). The user should deploy Special Service Tool: 09023-00101 to install the brake tube as well as 2 way which needs to be torqued to 15 Nm (155 kgf-cm, 11 ft. lbs.). The brake master cylinder sub-assembly is then installed with its gasket using 2 nuts that reach 13 Nm (127 kgf-cm, 9 ft. lbs.). Use the special service tool to connect front brake tubes No.1 and No.2 before torquing them to 15 Nm (155 kgf-cm, 11 ft. lbs.). After this, install the actuator bracket bolt with 5.0 Nm (51 kgf-cm, 44 inch lbs. torque. Secure the brake pedal through connecting the push rod clevis with brake master cylinder push rod pin using a clip and return spring while using clips to join the two reservoir tube hoses. The w/converter inverter assembly and cowl top panel sub-assembly outer front with 7 bolts (torqued to 6.4 Nm (65 kgf-cm, 57 inch lbs.)) and 3 clamps and engine room R/B No.2 with 2 bolts (torqued to 8.4 Nm (86 kgf-cm, 74 inch lbs.)) need to be installed. Conclusively reinstall the windshield wiper motor and link assembly and front wiper arms before filling the brake fluid reservoir then bleeding the master cylinder with Special Service Tool: 09023-00101 then checking for leakage while inspecting the reservoir fluid level and adjusting brake pedal height and reserve distance and free play before reattaching the instrument panel finish panel sub-assembly lower and instrument panel register assembly No.1 and checking and clearing the DTC.