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Home >> Lexus >> 2005 >> 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 procedures, make sure that the ignition switch is OFF and depress the brake pedal more than 40 times.

HINT: When the power supply system's pressure is released, the pedal resistance decreases.

NOTICE:
^ As high pressure is applied to the brake actuator No. 1 tube, make sure that it does not deform.
^ Do not turn the ignition switch ON until the procedures are completed.

1. DRAIN BRAKE FLUID

NOTICE: Wash off brake fluid immediately if it comes in contact with any painted surface.

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 master cylinder.
SST 09023-00101





b. Attach identification tags to the lines or write down line connection locations so that the lines can be reconnected correctly.





c. Using SST and a wrench, disconnect the front brake line LH from the flexible hose.
SST 09023-00101





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





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





11. FIX BRAKE MASTER CYLINDER
a. Using SST, mount the master cylinder in a 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 Dull out the reservoir.
15. REMOVE BRAKE MASTER CYLINDER RESERVOIR FILLER CAP ASSEMBLY
16. REMOVE MASTER CYLINDER RESERVOIR GROMMET
a. Remove the 3 grommets from the master cylinder.





17. REMOVE BRAKE MASTER CYLINDER KIT
a. Pressing the master cylinder plug in with a screwdriver, use a pin or equivalent to pry out the snap ring from the hole in the master cylinder body. Then remove the snap ring with another screwdriver.

HINT: Tape the screwdriver tip before use.

b. Remove the piston by pulling it out as straight as possible.

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 a 5 mm hexagon wrench, remove the bolt and bracket.
19. REMOVE BRAKE ACTUATOR BRACKET NO.3
a. Disconnect the level warning switch connector from the bracket.
b. Using a 5 mm hexagon wrench, remove the bolt and bracket.





20. REMOVE BRAKE ACTUATOR TUBE NO.1
a. Using SST, remove the tube.
SST 09023-00101
21. REMOVE BRAKE ACTUATOR HOSE
a. Slide the 2 clips and remove the hose and 2 clips.
22. REMOVE BRAKE MASTER CYLINDER UNION NO.1
a. Remove the union bolt, 2 gaskets and union.
23. REMOVE BRAKE MASTER CYLINDER UNION NO.2
a. Remove the union bolt, 2 gaskets and union.





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





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





30. FIX BRAKE BOOSTER W/ACCUMULATOR PUMP ASSEMBLY
a. Place the pump in a vise with a cloth, as shown in the illustration.





31. REMOVE BRAKE BOOSTER ACCUMULATOR ASSEMBLY
a. Using SST, remove the accumulator.
SST 09318-12010
b. Remove the accumulator pipe, compression spring and O-ring.

NOTICE: Keep the pump free from foreign matter.





32. INSPECT BRAKE BOOSTER PUMP ASSEMBLY
a. Connect the positive (+) battery lead to terminal 1 of the pump motor, and the negative (-) battery lead to terminal 2.
b. Check the pump operation.
If the result is not as specified, replace the pump.





33. DISPOSE OF BRAKE BOOSTER ACCUMULATOR ASSEMBLY
a. Discharge the high pressure gas from the accumulator.
1. Mount the accumulator in a vise.
2. Set a saw to the area to be cut. Cover the saw with a cloth.
3. Gradually cut the accumulator body.

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

34. FIX BRAKE BOOSTER PUMP ASSEMBLY
a. Mount the pump in a vise with a cloth.
35. INSTALL BRAKE BOOSTER ACCUMULATOR ASSEMBLY
a. Install the accumulator pipe, compression spring and new O-ring.

NOTICE: Keep the pump free from foreign matter.





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 a 5 mm hexagon wrench, install the 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 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 booster.
39. INSTALL BRAKE BOOSTER PUMP BRACKET
a. Using a 5 mm hexagon wrench, install the bracket with the bolt.
Torque: 12 Nm (122 kgf-cm, 9 ft. lbs.)
40. INSTALL BRAKE BOOSTER PUMP BRACKET NO.3
a. Using a 5 mm hexagon wrench, install the bracket with the 2 bolts.
Torque: 12 Nm (122 kgf-cm, 9 ft. lbs.)





41. INSPECT BRAKE BOOSTER PUMP BRACKET CLEARANCE
a. When installing the bracket, use a feeler gauge to adjust the clearances A, B, D and E under the following conditions:
1. The clearances are within the C range.





2. The clearances are within the specified ranges in the graphs below.
C range: 0.1 to 0.4 mm (0.004 to 0.016 inch)





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





46. INSTALL BRAKE ACTUATOR TUBE NO.1
a. Using SST, install the tube.
SST 09023-00101
Torque:
15 Nm (155 kgf-cm, 11 ft. lbs.) without SST
14 Nm (143 kgf-cm, 10 ft. lbs.) with SST

HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 inch).

47. INSTALL BRAKE ACTUATOR BRACKET NO.1
a. Using a 5 mm hexagon wrench, install the bracket with the bolt.
Torque: 8.5 Nm (87 kgf-cm, 75 inch lbs.)
48. INSTALL BRAKE ACTUATOR BRACKET NO.3
a. Using a 5 mm hexagon wrench, install the bracket with the bolt.
Torque: 7.8 Nm (80 kgf-cm, 69 inch lbs.)
b. Connect the level warning switch connector to the bracket.
49. INSTALL BRAKE MASTER CYLINDER KIT
a. Apply lithium soap base glycol grease to new piston and plug.
b. Install the piston and plug.
c. Pressing the plug, install a new snap ring.
50. INSTALL MASTER CYLINDER RESERVOIR GROMMET
a. Apply lithium soap base glycol grease to 3 new grommets.
b. Install the 3 grommets to the reservoir.
51. INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY
a. Install the reservoir 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 push rod clevis.
55. INSTALL BRAKE BOOSTER GASKET
a. Install a new gasket to the master cylinder.
56. INSTALL BRAKE MASTER CYLINDER
a. Install the master cylinder with the 4 nuts.
Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.)





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





c. Using SST and a wrench, connect the front brake line LH to the flexible hose.
SST 09023-00101
Torque:
15 Nm (155 kgf-cm, 11 ft. lbs.) without SST
14 Nm (143 kgf-cm, 10 ft. lbs.) with SST

HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 inch).





d. Using SST, connect each brake line to the correct position of the master cylinder, as shown in the illustration.
SST 09023-00101
Torque:
15 Nm (155 kgf-cm, 11 ft. lbs.) without SST
14 Nm (143 kgf-cm, 10 ft. lbs.) with SST

HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 inch).





e. Connect the 5 connectors and harness clamp to the 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 AIR FROM BRAKE LINE
65. CHECK AND ADJUST BRAKE PEDAL HEIGHT
66. CHECK PEDAL FREE PLAY
67. CHECK PEDAL RESERVE DISTANCE
68. CHECK FLUID LEVEL IN RESERVOIR
69. CHECK BRAKE FLUID LEAKAGE
70. INSTALL FRONT WHEEL LH
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
71. CHECK BRAKE MASTER CYLINDER OPERATION



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