Brake Booster (For Tmt Made) Installation

Temporarily install the lock nut and brake master cylinder push rod clevis to the brake booster assembly.

HINT:

Tighten the lock nut after adjusting the brake pedal height.

Install a new brake booster gasket to the brake booster.

Install the booster with the 4 nuts.

Torque:

14 N*m{145 kgf*cm, 10 ft.*lbf}

Install the push rod clevis to the brake booster.

Apply a light coat of lithium soap base glycol grease to the clevis pin.

Install the clevis pin and a new clip.

NOTICE:

The clip must be installed as shown in the illustration.

Install the return spring.

Install a new grommet and vacuum check valve to the booster.

Connect the vacuum hose.

Install the vacuum warning switch to the booster and connect the vacuum warning switch connector.

Torque:

14 N*m{139 kgf*cm, 10 ft.*lbf}

Set SST on the master cylinder and lower the rod of SST until it just touches the piston.

SST

09737-00013

HINT:

SST 09737-00012 can also be used.

Apply chalk to the flat tip of the rod of SST. Turn SST upside down and measure the clearance between the brake booster push rod and SST.

Standard clearance:

0 mm (0 in.)

If the clearance is not as specified, adjust the length by holding the rod using SST and turning the tip of the rod using a 7 mm socket driver.

SST

09737-00020

NOTICE:

Check the push rod clearance again after adjustment.

Bleed the brake master cylinder.

1. Remove the brake master cylinder reservoir filler cap assembly.
   

2. Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.
   

   Fluid:

   SAE J1703 or FMVSS No. 116 DOT 3
   

3. Using a union nut wrench, disconnect the 2 brake tubes from the master cylinder.
   





4. Slowly depress and hold the brake pedal.
   





5. Block the tube holes with your fingers, and then release the brake pedal.
   

6. Remove your fingers, slowly depress and hold the brake pedal, block the tube holes with your fingers again, and then release the brake pedal. Repeat this step 3 or 4 times.
   

7. Using a union nut wrench, connect the 2 brake tubes to the brake master cylinder assembly.
   

   Torque:

   15 N*m{155 kgf*cm, 11 ft.*lbf}

   NOTICE:

   Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (HILUX_TGN26 RM000004QR1006X.html).

Bleed the load sensing proportioning valve.

1. Remove the bleeder plug cap.
   

2. Connect a vinyl tube to the bleeder plug.
   

3. Depress the pedal several times, and then loosen the bleeder plug with the pedal depressed.
   

4. When fluid stops coming out, immediately tighten the bleeder plug. Then release the pedal.
   

5. Repeat the 2 previous steps until all the air in the brake fluid is gone.
   

6. Tighten the bleeder plug.
   

   Torque:

   11 N*m{107 kgf*cm, 8 ft.*lbf}

7. Install the bleeder plug cap.
   

Bleed the brake line.

1. Remove the bleeder plug cap.
   

2. Connect a vinyl tube to the bleeder plug.
   

3. Depress the brake pedal several times, and then loosen the bleeder plug with the pedal depressed.*1
   

4. When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal.*2
   

5. Repeat *1 and *2 until all the air in the fluid is completely bled out.
   

6. Tighten the bleeder plug completely.
   

   Torque:

   for Front Brake:

   11 N*m{110 kgf*cm, 8 ft.*lbf}

   for Rear Brake:

   10 N*m{102 kgf*cm, 7 ft.*lbf}

7. Repeat the above procedure for each wheel to bleed the brake line.
   

8. Install the bleeder plug cap.
   

Check for brake fluid leaks.

Check the brake fluid level in the reservoir (HILUX_TGN26 RM0000010K400VX_01_0001.html).

Remove the bleeder plug cap of the release cylinder.

Connect a vinyl tube to the bleeder plug.

Depress the clutch pedal several times, and then loosen the bleeder plug while the pedal is depressed.

When fluid no longer comes out, tighten the bleeder plug, and then release the clutch pedal.

Repeat the previous 2 steps until all the air in the fluid is completely bled.

Tighten the bleeder plug.

Torque:

11 N*m{110 kgf*cm, 8 ft.*lbf}

Install the bleeder plug cap.

Check that all the air has been bled from the clutch line.