OEM 2005 Toyota Sienna Brake Master Cylinder

2005 Toyota Sienna Parts Questions & Experts Answers

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

  A: The first step to replace the Brake Master Cylinder Assembly requires front wheel removal and draining the brake fluid and cleaning up any liquid that touches painted areas. Begin by disconnecting the battery negative terminal before removing the front door scuff plate LH along with the cowl side trim board LH (after removing the nut) then the instrument panel finish panel sub-assembly lower LH (removing 2 bolts) and the instrument panel safety pad insert sub-assembly No.1 (4 bolts removal needed). The technician should proceed by taking out the cowl top panel sub-assembly outer front along with the air cleaner assembly with hose and brake actuator assembly (with or without VSC requiring Special Service Tool: 09023-00101). Detach the brake lines by removing all front brake tubes starting with No.1 then No.2, No.3, No.4 and proceed to remove both rear brake tubes No.1 and No.2. First detach the push rod pin from the brake booster push rod before disconnection of the brake master cylinder reservoir hose and vacuum hose from the brake vacuum check valve assembly. The brake booster equipped with the master cylinder can be extracted after taking out four clevis nuts through which the brake booster with master cylinder follows the removal of a brake booster gasket and brake vacuum check valve assembly. Place the new brake vacuum check valve assembly together with check valve grommet onto the replacement parts before adding a fresh brake booster gasket. Reinstall the brake master cylinder assembly through its 4 nuts while torquing them to 13 Nm (130 kgf-cm, 9 ft. lbs.), reconnect the brake master cylinder reservoir hose and vacuum hose and insert the push rod pin. The brake lines need reattachment with front brake tubes at 15 Nm (155 kgf-cm, 11 ft. lbs.) tension and rear brake tubes at the same torque specification. To finish up the installation proceed by fitting the brake actuator assembly (with or without VSC), attaching the air cleaner assembly and its hose then filling the brake fluid reservoir before using Special Service Tool: 09023-00101 to bleed the master cylinder followed by bleeding the brake line. Brake fluid reservoir needs inspection for proper fluid levels while checking whether fluid is leaking from any area. Installation of the instrument panel safety pad insert sub-assembly No.1 requires 4 bolts at the same time as the instrument panel finish panel sub-assembly lower LH uses 2 bolts for attachment. Attach the cowl side trim board LH with a nut and the front door scuff plate LH and the cowl top panel sub-assembly outer front. Reinstall the front wheel after torquing it to 103 Nm (1,050 kgf-cm, 76 ft. lbs.). Then inspect the brake pedal height and test the brake actuator with the Toyota hand-held tester.