OEM 2007 Toyota Prius Brake Master Cylinder

2007 Toyota Prius Parts Questions & Experts Answers

• Q: How to service and repair the brake master cylinder on 2007 Toyota Prius?

  A: Service and repair of the brake master cylinder starts by disassembling the windshield wiper motor and link while setting the brake control (ECB) with power switch OFF and No. 1 and No. 2 motor relays removed to stop air intrusion during bleeding operations. Two bolts securing the outer front cowl top panel sub-assembly must be removed before removing the engine room No. 2 R/B followed by disconnection of three clamps and seven bolts. First drain the brake fluid and then proceed to remove both the inverter along with the converter followed by the No. 1 instrument panel register assembly and lower instrument panel finish panel sub-assembly. Brake return spring together with clip and push rod pin must be taken off from the brake master cylinder subassembly and a push rod clevis needs to be separated from the brake pedal. First drain the actuator bracket bolt after removing two reservoir hose tubes alongside four clips. The removal process of the No. 1 front brake tube and No. 2 front brake tube requires Special Service Tool: 09023-00101. You will need Special Service Tool: 09023-00101 to remove the brake tube and 2-way from the brake master cylinder. Before this step, remove 2 nuts, brake master cylinder gasket and the brake master cylinder from its bracket. To perform this task start by removing the screw and then the No. 1 brake master cylinder union and 2 grommets. Finally remove the push rod clevis by loosening the clevis lock nut. Order the installation process by connecting the brake master cylinder to the push rod clevis before tightening the lock nut while lubricating both new grommets with lithium soap base glycol grease. Install the No. 1 brake master cylinder union after placing the grommets and a torque should be set to 1.8 Nm (18 kgf-cm, 16 inch lbs.). First install the brake tube and 2-way to the brake master cylinder with a torque of 15 Nm (155 kgf-cm, 11 ft. lbs.) using Special Service Tool: 09023-00101. Next install the brake master cylinder onto the bracket with 2 nuts at a torque of 13 Nm (127 kgf-cm, 9 ft. lbs.). Should follow by placing the gasket in between both parts. Install the No. 2 front brake tube to the clamp and brake master cylinder with Special Service Tool: 09023-00101 and a torque of 15 Nm (155 kgf-cm, 11 ft. lbs.). Then connect the No. 1 front brake tube at the same torque. After tightening the bolt on the actuator bracket to 5.0 Nm (51 kgf-cm, 44 inch lbs.), install the 2 reservoir tube hoses with 4 clips, attach the push rod clevis to the brake pedal with the push rod pin, and put the clip and brake pedal return spring into place. Reinstall the inverter with converter while securing the outer front cowl top panel sub-assembly with 7 bolts at 6.4 Nm (65 kgf-cm, 57 inch lbs.) torque and install the engine room No. 2 R/B with 2 bolts at 8.4 Nm (86 kgf-cm, 74 inch lbs.). Finishing the service requires reinstalling the windshield wiper motor and links followed by brake fluid filling in the reservoir along with master cylinder and stroke simulator air bleeding to check for leakages and inspect the fluid level. Adjust the brake pedal height, free play and reserve distance and restore the lower instrument panel finish panel sub-assembly and No. 1 instrument panel register assembly, and check and clear DTC.