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Home >> Lexus >> 2007 >> SC 430 V8-4.3L (3UZ-FE) >> Repair and Diagnosis >> Brakes and Traction Control >> Power Brake Assist >> Hydraulic Brake Booster >> Service and Repair >> Overhaul

Overhaul

HYDRAULIC BRAKE BOOSTER

COMPONENTS

COMPONENTS (Part 1):




COMPONENTS (Part 2):




COMPONENTS (Part 3):





DISASSEMBLY

NOTICE: As high pressure will be applied to the No. 1 brake actuator tube, make sure that it does not deform.

1. REMOVE BRAKE BOOSTER GASKET
(a) Remove the gasket from the master cylinder.





2. FIX BRAKE MASTER CYLINDER SUB-ASSEMBLY
(a) Using SST, mount the master cylinder in a vise.
SST 09630-00014 (09631-00142), 09950-60010 (09951-00180, 09951-00190)

3. REMOVE MASTER CYLINDER PUSH ROD CLEVIS
(a) Loosen the lock nut, and then remove the push rod clevis and lock nut.

4. REMOVE MASTER CYLINDER BOOT
5. REMOVE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY
(a) Remove the 3 screws and pull out the reservoir.

6. REMOVE BRAKE MASTER CYLINDER RESERVOIR FILLER CAP ASSEMBLY
7. REMOVE MASTER CYLINDER RESERVOIR GROMMET
(a) Remove the 3 grommets from the master cylinder.





8. REMOVE BRAKE MASTER CYLINDER KIT
(a) While 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.

9. REMOVE NO. 1 BRAKE ACTUATOR BRACKET
(a) Using a 5 mm hexagon wrench, remove the bolt and bracket.

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





11. REMOVE NO. 1 BRAKE ACTUATOR TUBE
(a) Using SST, remove the tube.
SST 09023-00101

NOTICE: As high pressure will be applied to the No. 1 brake actuator tube, make sure that it does not deform.

12. REMOVE BRAKE ACTUATOR HOSE
(a) Slide the 2 clips and remove the hose and 2 clips.

13. REMOVE NO. 1 BRAKE MASTER CYLINDER UNION
(a) Remove the union bolt, 2 gaskets and union.

14. REMOVE NO. 2 BRAKE MASTER CYLINDER UNION
(a) Remove the union bolt, 2 gaskets and union.





15. REMOVE BRAKE CONTROL WIRE
(a) Remove the 4 screws.
(b) Disconnect the clamp and remove the wire.

16. REMOVE NO. 3 BRAKE BOOSTER PUMP BRACKET
(a) Using a 5 mm hexagon wrench, remove the 2 bolts and bracket.

17. REMOVE BRAKE BOOSTER PUMP BRACKET
(a) Hold the accumulator pump.
(b) Using a 5 mm hexagon wrench, remove the bolt and bracket.

18. REMOVE BRAKE BOOSTER W/ACCUMULATOR PUMP ASSEMBLY
(a) Remove the booster.

19. REMOVE NO. 1 BRAKE BOOSTER PUMP BRACKET
(a) Remove the bolt and bracket.
(b) Remove the 2 washers, 3 bushes, 2 collars and shaft.





20. REMOVE NO. 2 BRAKE BOOSTER PUMP BRACKET
(a) Using a 5 mm hexagon wrench, remove the 2 bolts and bracket.





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





22. 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.

REASSEMBLY

NOTICE: As high pressure will be applied to the No. 1 brake actuator tube, make sure that it does not deform.

1. FIX BRAKE BOOSTER PUMP ASSEMBLY
(a) Mount the pump in a vise with a cloth.





2. 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 N*m (550 kgf*cm, 36 ft.*lbf)

3. INSTALL NO. 2 BRAKE BOOSTER PUMP BRACKET
(a) Install the bush.
(b) Using a 5 mm hexagon wrench, install the bracket with the 2 bolts.
Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf)





4. INSTALL NO. 1 BRAKE BOOSTER PUMP BRACKET
(a) Install the shaft, 2 collars, 2 bushes and 2 washers.
(b) Install the bracket with the bolt.
Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf)

5. INSTALL BRAKE BOOSTER W/ACCUMULATOR PUMP ASSEMBLY
(a) Install the booster.

6. INSTALL BRAKE BOOSTER PUMP BRACKET
(a) Using a 5 mm hexagon wrench, install the bracket with the bolt.
Torque: 12 N*m (122 kgf*cm, 8.9 ft.*lbf)

7. INSTALL NO. 3 BRAKE BOOSTER PUMP BRACKET
(a) Using a 5 mm hexagon wrench, install the bracket with the 2 bolts.
Torque: 12 N*m (122 kgf*cm, 8.9 ft.*lbf)








8. INSPECT BRAKE BOOSTER PUMP BRACKET CLEARANCE
(a) When installing the brackets, use a feeler gauge to adjust the clearances A, B, D and E under the following conditions:
(1) The clearance "C" is within the C range.
C range: 0.1 to 0.4 mm (0.004 to 0.016 in.)
(2) The clearances "A, B, D, E" are within the specified ranges in the graphs below.





9. INSTALL BRAKE CONTROL WIRE
(a) Install a new wire with the 4 screws.
Torque: 1.7 N*m (17.5 kgf*cm, 15 in.*lbf) for brake master cylinder side 2.9 N*m (30 kgf*cm, 26 in.*lbf) for brake booster pump side
(b) Connect the wire harness clamp.

10. INSTALL NO. 1 BRAKE MASTER CYLINDER UNION
(a) Install 2 new gaskets and the union with the union bolt.
Torque: 32 N*m (326 kgf*cm, 23 ft.*lbf)

11. INSTALL NO. 2 BRAKE MASTER CYLINDER UNION
(a) Install 2 new gaskets and the union with the union bolt.
Torque: 32 N*m (326 kgf*cm, 23 ft.*lbf)

12. INSTALL BRAKE ACTUATOR HOSE
(a) Install the hose with the 2 clips.





13. INSTALL NO. 1 BRAKE ACTUATOR TUBE

NOTICE: As high pressure will be applied to the No. 1 brake actuator tube, make sure that it does not deform.

(a) Using SST, install the tube.
SST 09023-00101
Torque: 15 N*m (155 kgf*cm, 11 ft.*lbf) without SST 14 N*m (143 kgf*cm, 10 ft.*lbf) with SST

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

14. INSTALL NO. 1 BRAKE ACTUATOR BRACKET
(a) Using a 5 mm hexagon wrench, install the bracket with the bolt.
Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf)

15. INSTALL NO. 3 BRAKE ACTUATOR BRACKET
(a) Using a 5 mm hexagon wrench, install the bracket with the bolt.
Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf)
(b) Connect the level warning switch connector to the bracket.

16. INSTALL BRAKE MASTER CYLINDER KIT
(a) Apply lithium soap base glycol grease to a new piston and plug.
(b) Install the piston and plug.
(c) Pressing the plug, install a new snap ring.

17. INSTALL MASTER CYLINDER RESERVOIR GROMMET
(a) Apply lithium soap base glycol grease to 3 new grommets.
(b) Install the 3 grommets to the reservoir.

18. INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY
(a) Install the reservoir with the 3 screws.
Torque: 1.7 N*m (17.5 kgf*cm, 15 in.*lbf)

19. INSTALL BRAKE MASTER CYLINDER RESERVOIR FILLER CAP ASSEMBLY
20. INSTALL MASTER CYLINDER BOOT
21. INSTALL MASTER CYLINDER PUSH ROD CLEVIS
(a) Install the lock nut and push rod clevis.

22. INSTALL BRAKE BOOSTER GASKET
(a) Install a new gasket to the master cylinder.
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