Disassembly and Assembly

DISASSEMBLY





1. Place hydraulic brake booster in vise.
Using Special Service Tool (SST) 09630-00014 (09631-00142), 09950-60010 (09951-00180, 09951-00190) or equivalent, set the hydraulic brake booster in vise.
2. Remove reservoir and grommets.
a. Remove reservoir cap.
b. Remove the 3 set screws and pull out the reservoir.
Torque: 1.7 Nm (15.2 inch lbs.)
c. Remove the 3 grommets.
3. Remove clevis and cylinder boot.
a. Loosen the lock nut, then remove the clevis and lock nut.
Torque: 25 Nm (19 ft. lbs.)
b. Remove the cylinder boot.
4. Remove oil pressure sensor.
Torque: 81 Nm (60 ft. lbs.)





5. Remove pistons.
a. Pressing the piston in with a screwdriver, use a pin or an equivalent to push the snap ring from the hole in the body then remove it with another screwdriver.
b. Remove the No.1 and No.2 piston, pulling straight out, not at an angle.
c. Remove the O-ring and pistons cup from No.1 piston.

NOTICE: If pulled out and installed at an angle, there is a possibility that the cylinder bore could be damaged. At the time of reassembly, be careful not to damage the rubber lips on the pistons.

6. Remove actuator hose.
7. Remove 2 bolts and hangers.





8. Remove brake actuator tube No.1.
Using SST 09023-00100, remove the brake actuator tube No.1.
Torque: 15 Nm (11 ft. lbs.)
9. Remove booster pump and accumulator.
a. Remove the 2 screws and disconnect the wire harness connector from the booster assembly.
b. Remove the 3 bolts, No.1 accumulator bracket, No.2 accumulator bracket and booster pump and accumulator with the No.1 pump bracket.
c. Remove the bolt and No.1 pump bracket, and remove the 2 washers, 3 cushions, 2 collars and sleeve.
d. Remove the 2 bolts and No.2 pump bracket.





10. Remove accumulator from booster pump.
a. Using SST 09318-12010, remove the accumulator.
Torque: 54 Nm (36 ft. lbs.)
b. Remove the silencer tube, spring and ring.

DISPOSAL
1. Disposal method of accumulator.
a. Follow the procedures described below and drain the high pressure fluid from the accumulator.
b. Place the accumulator in a vise, cover it with a cloth over a saw then cut the accumulator body slowly.

CAUTION: Never cut at a stretch.

c. When the outer body of the accumulator is cut, gas discharges.


REASSEMBLY
Reassembly is in the reverse order of disassembly.








1. Install accumulator bracket.
When installing the accumulator bracket, adjust to ensure that clearance (A, B, D and E) shown in the illustration coresponds to each value in the graphs and are with in the C range, using a thickness gauge.
C Range: 0.1 - 0.4 mm (0.004 - 0.016 inch)