FREE REPAIR MANUALS & LABOR GUIDES 1982-2013 Vehicles
Courtesy of Operation CHARM: Car repair manuals for everyone.
Home >> Lexus >> 2003 >> SC 430 V8-4.3L (3UZ-FE) >> Repair and Diagnosis >> Brakes and Traction Control >> Hydraulic System >> Brake Master Cylinder >> Service and Repair

Brake Master Cylinder: Service and Repair





OVERHAUL

NOTICE: Before starting the work, make sure that the ignition switch is OFF and depress the brake pedal more than 40 times.

HINT: When a pressure in power supply system is released, reaction force becomes lightly.

NOTICE:
^ As high pressure is applied to the brake actuator No. 1 tube, never deform it.
^ Until the work is over, do not turn the ignition switch ON.

1. DRAIN BRAKE FLUID

NOTICE: Do not let brake fluid remain on a painted surface. Wash it off immediately.

2. REMOVE V-BANK COVER
3. REMOVE BRAKE MASTER CYLINDER COVER ASSEMBLY
4. REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY NO.1
5. REMOVE BRAKE PEDAL RETURN SPRING
6. REMOVE CLIP
7. REMOVE PUSH ROD PIN
8. REMOVE FRONT WHEEL LH
9. REMOVE BRAKE MASTER CYLINDER





a. Using SST, disconnect the 4 brake lines from the brake master cylinder.
SST 09023-00100





b. Use tags or make a memo to identify the place to reconnect.





c. Using SST and spanner, disconnect the front brake line LH from the flexible hose.
SST 09023-00100





d. Disconnect the 5 connectors and harness clamp from the brake master cylinder.





e. Remove the 2 nuts and separate the brake lines from the body.
f. Remove the 4 nuts and pull out the brake master cylinder assembly.
10. REMOVE BRAKE BOOSTER GASKET
a. Remove the brake booster gasket from the brake master cylinder.





11. FIX BRAKE MASTER CYLINDER
a. Using SST, set the brake master cylinder in vise.
SST 09630-00014 (09631-00142), 09950-60010 (09951-00180, 09951-00190)
12. REMOVE MASTER CYLINDER PUSH ROD CLEVIS
a. Loosen the lock nut, then remove the push rod clevis and lock nut.
13. REMOVE MASTER CYLINDER BOOT
14. REMOVE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY
a. Remove the 3 screws and pull out the master cylinder reservoir assembly.
15. REMOVE BRAKE MASTER CYLINDER RESERVOIR FILLER CAP ASSEMBLY
16. REMOVE MASTER CYLINDER RESERVOIR GROMMET
a. Remove the 3 reservoir grommets from the brake master cylinder assembly.





17. REMOVE BRAKE MASTER CYLINDER KIT
a. Pressing the brake master cylinder plug in with a screwdriver, use a pin or an equivalent to push the snap ring from the hole in the master cylinder body then remove it with another screwdriver.
b. Remove the piston, pulling straight out, not an angle.

NOTICE: If pulled out at an angle, there is a possibility that the cylinder bore could be damaged.

18. REMOVE BRAKE ACTUATOR BRACKET NO.1
a. Using hexagon wrench (5 mm), remove the bolt and brake actuator No. 1 bracket.
19. REMOVE BRAKE ACTUATOR BRACKET NO.3
a. Disconnect the level warning switch connector from the brake actuator No. 3 bracket.





20. REMOVE BRAKE ACTUATOR TUBE NO.1
a. Using SST, remove the brake actuator No. 1 tube.
SST 09023-00100
21. REMOVE BRAKE ACTUATOR HOSE
a. Slide the 2 clips and remove the brake actuator hose and 2 clips.
22. REMOVE BRAKE MASTER CYLINDER UNION NO.1
a. Remove the union bolt, 2 gasket and union No. 1.
23. REMOVE BRAKE MASTER CYLINDER UNION NO.2
a. Remove the union bolt, 2 gasket and union No. 2.





24. REMOVE BRAKE CONTROL WIRE
a. Remove the 4 screws.
b. Disconnect the clamp and remove the brake control wire.
25. REMOVE BRAKE BOOSTER PUMP BRACKET NO.3
a. Using hexagon wrench (5 mm), remove the 2 bolts and brake booster pump bracket.
26. REMOVE BRAKE BOOSTER PUMP BRACKET NO.2
a. Hold the accumulator pump assembly, then using hexagon wrench (5 mm) and remove the bolt and brake booster pump bracket.
27. REMOVE BRAKE BOOSTER W/ACCUMULATOR PUMP ASSEMBLY
a. Remove the brake booster w/accumulator pump assembly.





28. REMOVE BRAKE BOOSTER PUMP BRACKET NO.1
a. Remove the bolt and brake booster pump bracket.
b. Remove the 2 washers, 3 bushes, 2 collars and shaft.
29. REMOVE BRAKE BOOSTER PUMP BRACKET NO.2
a. Using hexagon wrench (5 mm), remove the 2 bolts and brake booster pump No. 2 bracket.





30. FIX BRAKE BOOSTER W/ACCUMULATOR PUMP ASSEMBLY
a. Place the booster pump with a cloth shown in the illustration on the left.
31. REMOVE BRAKE BOOSTER ACCUMULATOR ASSEMBLY





a. Using SST, remove the accumulator.
SST 09310-12010
b. Remove the brake booster accumulator pipe, compression spring and O-ring.

NOTICE: Ensure no foreign matter enters the pump.





32. INSPECT BRAKE BOOSTER PUMP ASSEMBLY
a. Connect the positive (+) lead from the battery to terminal 1 of pump motor, and the negative (-) lead to terminal 2.
b. Check that the brake booster pump operation.





33. DISPOSE OF BRAKE BOOSTER ACCUMULATOR ASSEMBLY
a. Follow the procedures described and drain the high pressure gas from the accumulator.
b. Place the accumulator in a vise, cover it with a cloth over a saw then nut the accumulator body slowly.

CAUTION: Never cut at a stretch.

c. When the outer body of the accumulator is out, gas discharges.
34. FIX BRAKE BOOSTER PUMP ASSEMBLY
a. Place the booster pump with a cloth shown in the illustration on the left.
35. INSTALL BRAKE BOOSTER ACCUMULATOR ASSEMBLY
a. Install the brake booster accumulator pipe, compression spring and new O-ring.

NOTICE: Ensure no foreign matter enters the pump.





b. Using SST, install the accumulator.
SST 09318-12010
Torque: 54 Nm (550 kgf-cm, 36 ft. lbs.)
36. INSTALL BRAKE BOOSTER PUMP BRACKET NO.2
a. Using hexagon wrench (5 mm), install the brake booster pump No. 2 bracket with the 2 bolts.
Torque: 7.8 Nm (80 kgf-cm, 69 inch lbs.)





37. INSTALL BRAKE BOOSTER PUMP BRACKET NO.1
a. Install the shaft, 2 collars, 3 bushes and 2 washers.
b. Install the brake booster pump bracket with the bolt.
Torque: 7.8 Nm (80 kgf-cm, 69 inch lbs.)
38. INSTALL BRAKE BOOSTER W/ACCUMULATOR PUMP ASSEMBLY
a. Install the brake booster w/accumulator pump assembly.
39. INSTALL BRAKE BOOSTER PUMP BRACKET NO.2
a. Using hexagon wrench (5 mm), install the brake booster pump bracket No. 1 and brake booster pump bracket No. 2 with the bolt.
Torque: 12 Nm (122 kgf-cm, 8.9 ft. lbs.)
40. INSTALL BRAKE BOOSTER PUMP BRACKET NO.3
a. Using hexagon wrench (5 mm), install the brake booster pump bracket with the 2 bolts.
Torque: 12 Nm (122 kgf-cm, 8.9 ft. lbs.)








41. INSPECT BRAKE BOOSTER PUMP BRACKET CLEARANCE
a. When installing the brake booster bracket, adjust to ensure that clearance.(A, B, D and E) shown in the illustration on the left corresponds to each value in the graphs and are within the C range, using a thickness gauge.
C Range: 0.1 - 0.4 mm (0.004 - 0.016 inch)





42. INSTALL BRAKE CONTROL WIRE
a. Install a new brake control wire with the 4 screws.
Torque:
Master cylinder side: 1.7 Nm (17.5 kgf-cm, 15 inch lbs.)
Booster pump side: 2.9 Nm (30 kgf-cm, 26 inch lbs.)
b. Connect the wire harness clamp.
43. INSTALL BRAKE MASTER CYLINDER UNION NO.1
a. Install new 2 gaskets and union No. 1 with the union bolt.
Torque: 32 Nm (326 kgf-cm, 23 ft. lbs.)
44. INSTALL BRAKE MASTER CYLINDER UNION NO.2
a. Install 2 new gaskets and union No. 2 with the union bolt.
Torque: 32 Nm (326 kgf-cm, 23 ft. lbs.)
45. INSTALL BRAKE ACTUATOR HOSE
a. Install the brake actuator hose and 2 clips.





46. INSTALL BRAKE ACTUATOR TUBE NO.1
a. Using SST, install the brake actuator No. 1 tube.
SST 09023-00100
Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.)
47. INSTALL BRAKE ACTUATOR BRACKET NO.1
a. Using hexagon wrench (5 mm), install the brake actuator No. 1 bracket with the bolt.
Torque: 8.5 Nm (87 kgf-cm, 75 inch lbs.)
48. INSTALL BRAKE ACTUATOR BRACKET NO.3
a. Using hexagon wrench (5 mm), install the brake actuator No. 3 bracket with the bolt.
Torque: 7.8 Nm (80 kgf-cm, 69inch lbs.)
b. Connect the level warning switch connector to the brake actuator No. 3 bracket.
49. INSTALL BRAKE MASTER CYLINDER KIT
a. Apply lithium soap base glycol grease to new brake booster piston and plug.
b. Install the piston and brake booster plug.
c. Pressing brake booster plug, and install a new snap ring.
50. INSTALL MASTER CYLINDER RESERVOIR GROMMET
a. Apply lithium soap base glycol grease to new 3 grommets.
b. Install the 3 grommets to the reservoir assembly.
51. INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY
a. Install the master cylinder reservoir assembly with the 3 screws.
Torque: 1.7 Nm (17.5 kgf-cm, 15 inch lbs.)
52. INSTALL BRAKE MASTER CYLINDER RESERVOIR FILLER CAP ASSEMBLY
53. INSTALL MASTER CYLINDER BOOT
54. INSTALL MASTER CYLINDER PUSH ROD CLEVIS
a. Install the lock nut and master cylinder clevis.
55. INSTALL BRAKE BOOSTER GASKET
a. Install a new brake booster gasket to the master cylinder.
56. INSTALL BRAKE MASTER CYLINDER
a. Install the brake master cylinder assembly with the 4 nuts.
Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.)





b. Install the brake lines with the 2 nuts to the body.
Torque: 4.9 Nm (50 kgf-cm, 43 inch lbs.)





c. Using SST and spanner, connect the front brake line LH to the flexible hose.
SST 09023-00100
Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.)





d. Using SST, connect the each brake line to the correct position of brake master cylinder, as shown in the illustration.
SST 09023-00100
Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.)





e. Connect the 5 connectors and harness clamp to the brake master cylinder.
57. INSTALL PUSH ROD PIN
58. INSTALL CLIP
59. INSTALL BRAKE PEDAL RETURN SPRING
60. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY NO.1
61. INSTALL BRAKE MASTER CYLINDER COVER ASSEMBLY
62. INSTALL V-BANK COVER
63. FILL RESERVOIR WITH BRAKE FLUID
64. BLEED MASTER CYLINDER
SST 09023-00100
65. BLEED BRAKE LINE
66. CHECK AND ADJUST BRAKE PEDAL HEIGHT
67. CHECK PEDAL FREE PLAY
68. CHECK PEDAL RESERVE DISTANCE
69. CHECK FLUID LEVEL IN RESERVOIR
70. CHECK BRAKE FLUID LEAKAGE
71. INSTALL FRONT WHEEL LH
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
72. CHECK BRAKE MASTER CYLINDER OPERATION

pro multis Credits:Operation CHARM About Operation CHARM