OEM 2005 Toyota RAV4 Brake Booster

2005 Toyota RAV4 Parts Questions & Experts Answers

• Q: How to service and repair the brake booster assembly on 2005 Toyota RAV4?

  A: The brake booster service process starts by unfastening the master cylinder while disconnecting the vacuum hose from the booster unit and the pedal return spring followed by removing the clip and clevis pin that leads to taking out the brake booster through 4 nut and clevis removal until it can be pulled out with its gasket. While installing the booster you should start with new gasket and booster followed by clevis attachment to the operating rod followed by booster installation nut torque application at 13 Nm (130 kgf-cm, 9 ft.lbs.). Attach both the clevis pin into the clevis and brake pedal and fasten it using the clip before repositioning the pedal return spring. Using a new gasket on the master cylinder while setting Special Service Tool: 09737-00011 on the gasket will help adjust the booster push rod length by lowering the pin until it touches the piston barely. Place Special Service Tool: 09737-00011 upside down on the booster to measure the booster push rod and pin head clearance which must be 0 mm (0 in.). Special Service Tool: 09737-00020 should be used to adjust the booster push rod length for it to barely reach the pin head while keeping the brake pedal sufficiently depressed. The next steps include connecting the vacuum hose to the brake booster before you install the master cylinder followed by brake fluid addition to the reservoir and brake system bleeding procedure. Proceed with the following inspection method: first inspect for leaks and second verify and tune the brake pedal before locking the clevis nut to 26 Nm (260 kgf-cm, 20 ft. lbs.). Afterward conduct an operational check.