Land Cruiser URJ200 URJ202 GRJ200 VDJ200 - BRAKE SYSTEM OTHER

HYDRAULIC BRAKE BOOSTER (for RHD) - DISASSEMBLY

1. REMOVE NO. 1 BRAKE ACTUATOR BRACKET
Hydraulic Brake Booster (For Rhd) - Disassembly. BRAKE SYSTEM OTHER. Land Cruiser URJ200  URJ202 GRJ200 VDJ200

Using a 5 mm hexagon wrench, remove the bolt and No. 1 brake actuator bracket.

Hydraulic Brake Booster (For Rhd) - Disassembly. BRAKE SYSTEM OTHER. Land Cruiser URJ200  URJ202 GRJ200 VDJ200

Using a screwdriver, disconnect the brake fluid level warning switch connector from the No. 1 brake actuator bracket.

2. REMOVE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY
Hydraulic Brake Booster (For Rhd) - Disassembly. BRAKE SYSTEM OTHER. Land Cruiser URJ200  URJ202 GRJ200 VDJ200

Using a pin punch and hammer, remove the pin from the brake master cylinder reservoir.

Hydraulic Brake Booster (For Rhd) - Disassembly. BRAKE SYSTEM OTHER. Land Cruiser URJ200  URJ202 GRJ200 VDJ200

Remove the screw and pull out the brake master cylinder reservoir sub-assembly.

Remove the master cylinder reservoir filler cap.

3. REMOVE MASTER CYLINDER RESERVOIR GROMMET
Hydraulic Brake Booster (For Rhd) - Disassembly. BRAKE SYSTEM OTHER. Land Cruiser URJ200  URJ202 GRJ200 VDJ200

Remove the 3 reservoir grommets from the master cylinder reservoir.

4. REMOVE NO. 1 BRAKE ACTUATOR HOSE
Hydraulic Brake Booster (For Rhd) - Disassembly. BRAKE SYSTEM OTHER. Land Cruiser URJ200  URJ202 GRJ200 VDJ200

Using needle nose pliers, slide the 2 clips and remove the brake actuator hose and 2 clips.

5. REMOVE NO. 1 BRAKE ACTUATOR TUBE
Hydraulic Brake Booster (For Rhd) - Disassembly. BRAKE SYSTEM OTHER. Land Cruiser URJ200  URJ202 GRJ200 VDJ200

Using a union nut wrench, remove the No. 1 brake actuator tube.

6. REMOVE BRAKE BOOSTER WITH ACCUMULATOR PUMP ASSEMBLY
Hydraulic Brake Booster (For Rhd) - Disassembly. BRAKE SYSTEM OTHER. Land Cruiser URJ200  URJ202 GRJ200 VDJ200

Using a screwdriver, remove the 2 plugs.

Hydraulic Brake Booster (For Rhd) - Disassembly. BRAKE SYSTEM OTHER. Land Cruiser URJ200  URJ202 GRJ200 VDJ200

Remove the 2 screws and disconnect the wire harnesses from the master cylinder solenoid.

Hydraulic Brake Booster (For Rhd) - Disassembly. BRAKE SYSTEM OTHER. Land Cruiser URJ200  URJ202 GRJ200 VDJ200

Using a screwdriver, remove the clip.

Hydraulic Brake Booster (For Rhd) - Disassembly. BRAKE SYSTEM OTHER. Land Cruiser URJ200  URJ202 GRJ200 VDJ200

Remove the brake booster with accumulator pump assembly from the brake master cylinder.

Remove the 2 brake booster pump collars and 2 brake booster pump bushes from the brake booster with accumulator pump assembly.

Hydraulic Brake Booster (For Rhd) - Disassembly. BRAKE SYSTEM OTHER. Land Cruiser URJ200  URJ202 GRJ200 VDJ200

Using a 4 mm hexagon wrench, remove the 2 pins.

7. REMOVE NO. 1 BRAKE BOOSTER PUMP BRACKET
Hydraulic Brake Booster (For Rhd) - Disassembly. BRAKE SYSTEM OTHER. Land Cruiser URJ200  URJ202 GRJ200 VDJ200

Using a 5 mm hexagon wrench, remove the 2 bolts and No. 1 brake booster pump bracket from the brake master cylinder solenoid.

Remove the brake booster pump bush from the No. 1 brake booster pump bracket.

8. REMOVE BRAKE BOOSTER ACCUMULATOR PIPE
Hydraulic Brake Booster (For Rhd) - Disassembly. BRAKE SYSTEM OTHER. Land Cruiser URJ200  URJ202 GRJ200 VDJ200

Secure the brake booster with accumulator pump assembly in a vise.

Remove the brake booster accumulator.

Remove the O-ring from the brake booster accumulator.

  • NOTICE:
  • Ensure no foreign matter enters the pump.

Remove the brake booster accumulator pipe and compression spring.

9. REMOVE MASTER CYLINDER SOLENOID
Hydraulic Brake Booster (For Rhd) - Disassembly. BRAKE SYSTEM OTHER. Land Cruiser URJ200  URJ202 GRJ200 VDJ200

Remove the 6 bolts and master cylinder solenoid.

Hydraulic Brake Booster (For Rhd) - Disassembly. BRAKE SYSTEM OTHER. Land Cruiser URJ200  URJ202 GRJ200 VDJ200

Remove the gasket.

10. REMOVE MASTER CYLINDER PUSH ROD CLEVIS
Hydraulic Brake Booster (For Rhd) - Disassembly. BRAKE SYSTEM OTHER. Land Cruiser URJ200  URJ202 GRJ200 VDJ200

Loosen the lock nut on the rod operating adapter, and remove the push rod clevis and lock nut.

Hydraulic Brake Booster (For Rhd) - Disassembly. BRAKE SYSTEM OTHER. Land Cruiser URJ200  URJ202 GRJ200 VDJ200

Loosen the lock nut on the brake master cylinder side, and remove the rod operating adapter and lock nut.

11. REMOVE MASTER CYLINDER BOOT
12. REMOVE BRAKE BOOSTER PISTON SUB-ASSEMBLY
Hydraulic Brake Booster (For Rhd) - Disassembly. BRAKE SYSTEM OTHER. Land Cruiser URJ200  URJ202 GRJ200 VDJ200

Pressing the piston in with a screwdriver, insert a pin or equivalent from the hole in the master cylinder body to hold the C-ring, and then remove it with another screwdriver.

  • HINT:
  • Tape the screwdriver tip before use.

Remove the plug from the piston.

Remove the piston by pulling it straight out, not at an angle.

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