Brake Actuator Assembly: Replacement

DRAIN BRAKE FLUID
NOTE: Do not let brake fluid remain on a painted surface. Wash it off immediately.
REMOVE AIR CLEANER ASSEMBLY WITH HOSE
REMOVE BRAKE ACTUATOR WITH BRACKET
1. Using SST, disconnect the 6 brake lines from the actuator.
  
  Fig 1: Disconnecting Brake Lines From Actuator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09023-00100
2. Use tags or make a memo to identify the place to reconnect.
  
  Fig 2: Using Tags On Brake Lines
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST, disconnect the brake lines from the master cylinder, then remove the 2 brake lines.
  
  Fig 3: Disconnecting Brake Lines From Master Cylinder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09023-00100
4. Disconnect the brake actuator connector.
5. Remove the 3 nuts and brake actuator with bracket.
REMOVE BRAKE ACTUATOR ASSY
1. Remove the 2 nuts and brake actuator from the bracket.
2. Remove the 2 holders and 3 cushions from the brake actuator.
REMOVE BRAKE ACTUATOR BRACKET ASSY
1. Remove the tube clamp bolt from the bottom side of the actuator bracket.
  
  Fig 5: Removing Tube Clamp Bolt From Bottom Side Of Actuator Bracket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 4 bolts and brake actuator bracket.
  
  Fig 6: Removing Brake Actuator Bracket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BRAKE ACTUATOR BRACKET ASSY
1. Install the brake actuator bracket with the 4 bolts.
  
  Fig 7: Installing Brake Actuator Bracket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 19 N.m (194 kgf.cm, 14 ft.lbf)
2. Install the tube clamp to the bottom side of the brake actuator bracket with the bolt.
  Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)
INSTALL BRAKE ACTUATOR ASSY
1. Install the 3 cushions and 2 holders to the brake actuator.
2. Install the brake actuator to the bracket with the 2 nuts.
  
  Fig 8: Installing Tube Clamp To Bottom Side Of Brake Actuator Bracket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
INSTALL BRAKE ACTUATOR WITH BRACKET
1. Install the brake actuator with the 3 nuts.
  
  Fig 9: Connecting Brake Actuator Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 19 N.m (194 kgf.cm, 14 ft.lbf)
2. Connect the brake actuator connector.
3. Using SST, connect the 2 brake lines to the master cylinder.
  
  Fig 10: Connecting Brake Lines To Master Cylinder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09023-00100
  
  Torque: 15 N.m (155 kgf.cm, 11 ft.lbf)
4. Using SST, connect the each brake line to the correct position of brake actuator, as shown in Fig 11.
  
  Fig 11: Connecting Each Brake Line To Correct Position Of Brake Actuator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09023-00100
  
  Torque: 15 N.m (155 kgf.cm, 11 ft.lbf)
INSTALL AIR CLEANER ASSEMBLY WITH HOSE
FILL RESERVOIR WITH BRAKE FLUID
BLEED MASTER CYLINDER (See MASTER CYLINDER )
SST 09023-00100
BLEED BRAKE LINE (See BLEEDING BRAKE SYSTEM )
CHECK FLUID LEVEL
CHECK BRAKE FLUID LEAKAGE
CHECK BRAKE ACTUATOR ON HAND-HELD TESTER (See ON-VEHICLE INSPECTION )