Question 1

How to service and repair the brake master cylinder on Toyota 4Runner?

Accepted Answer

The first step for brake master cylinder service requires using a 5 mm hexagon wrench to detach the bolt from brake actuator bracket No. 1 and disconnecting the brake fluid level warning switch connector. Use a pin punch and hammer to remove the master cylinder reservoir sub-assembly pin followed by unscrewing the screw and pulling the assembly out, after which remove the master cylinder reservoir filler cap. Remove the three reservoir grommets that exist within the master cylinder reservoir sub-assembly. Using needle nose pliers slide the two brake actuator hose No. 1 clips then pull the hose as well as the clips off. Ctrlexe a union nut wrench to detach brake actuator tube No. 1 from the brake master cylinder. The brake booster attachment procedure for the accumulator pump assembly requires two plug removal with a screwdriver followed by unscrewing the two screws and disconnecting wire harnesses from the master cylinder solenoid before acquiring the assembly with the clip. Another step involves taking out the 2 brake booster pump collars and 2 brake booster pump bushes before removing 2 pins using a 4 mm hexagon wrench. Brace No. 2 connecting the brake booster pump requires removal through two 5 mm hexagon wrench bolts that need to be unscrewed before the pump bush can be taken off. To detach brake actuator bracket No. 3 from its bolt you should then mount the brake booster with accumulator pump assembly in a vise to eliminate the brake booster accumulator assembly and O-ring from the pump while safeguarding it from foreign objects. Sever the brake booster accumulator pipe after you have cut the compression spring. You can remove the master cylinder solenoid by first removing its 6 bolts together with the gasket above them. The process for master cylinder push rod clevis removal starts with loosening the lock nut on the rod operating adapter, proceeding to take out the clevis and lock nut and finally loosening the lock nut on the brake master cylinder side to remove the rod operating adapter and lock nut. Use a screwdriver to push the master cylinder piston while using a pin or equivalent to push the C-ring through the cylinder body hole before removing the piston directly without angling it to protect the cylinder bore.

Question 2

How to install the brake master cylinder on Toyota Tacoma?

Accepted Answer

Before installing the brake master cylinder check and modify the brake booster push rod according to specifications while verifying that brake booster interior remains empty from vacuum atmosphere by stopping the engine then pressing the brake pedal multiple times. Latch Special Service Tool: 09737-00013 onto the master cylinder sub-assembly before dropping the pin until the piston gets a minimal contact. Special Service Tool: 09737-00012 provides an alternative option to perform the task. Set Special Service Tool: 09737-00013 upside down onto the booster with its pin resting on the booster push rod while checking the clearance between the rod and the pin for a 0 mm (0 in.) standard measurement. Use Special Service Tool: 09737-00020 while holding the rod to alter the presentation by turning the tip using a 7 mm socket driver. The procedure involves installation of a new O-ring onto the brake master cylinder sub-assembly and its securement to the brake booster through tightening 2 nuts to 13 Nm (127 kgf-cm, 9 ft-lbf). Use a union nut wrench to apply torque of 20 Nm (199 kgf cm, 14 ft lbf) directly or 18 Nm (187 kgf cm, 13 ft lbf) when using the wrench when installing brake lines onto the master cylinder sub-assembly. The brake fluid level warning switch connector should be attached to the brake master cylinder sub-assembly while connecting the clutch reservoir tube to the manual transmission reservoir. Use a torque wrench to reattach the negative battery terminal with a force of 3.9 Nm but not exceeding 40 kgf-cm or 35 in-lbf. Brake fluid should be added to the reservoir after which the master cylinder bleeding process includes the brake line and brake actuator followed by a fluid level inspection of the reservoir. The last step involves checking for brake fluid leaks before inspecting brake pedal height along with free play and reserve distance.

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