Disassembly

BRAKE: HYDRAULIC BRAKE BOOSTER: 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

SST : 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 a union nut wrench, remove the tube.





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 NO.1

(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.