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Removal [01/2023 - ]: Procedure

  1. PRECAUTION 
    NOTE:

    After turning the engine switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work.

    Refer to PRECAUTION [11/2017 - ]

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
    NOTE:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

    Refer to INITIALIZATION [01/2023 - 10/2023] , or refer to INITIALIZATION [10/2023 - ]

  3. REMOVE FRONT WHEEL LH 

    Refer to REMOVAL [01/2023 - ]

  4. DRAIN BRAKE FLUID 
    NOTE:

    If brake fluid leaks onto any painted surface, immediately wash it off.

  5. SEPARATE NO. 3 ENGINE ROOM RELAY BLOCK ASSEMBLY 

    Refer to PROCEDURE - Step 2

  6. REMOVE WIRING HARNESS CLAMP BRACKET 

    Refer to PROCEDURE - Step 3

  7. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4

  8. REMOVE BRAKE MASTER CYLINDER O-RING 

    Refer to PROCEDURE - Step 5

  9. DISCONNECT UNION TO CHECK VALVE HOSE 
    1. Slide the clip and disconnect the union to check valve hose from the brake booster assembly.
      GTY825146Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE FRONT NO. 3 BRAKE TUBE 
    1. Use tags or make a memo to identify the places to reconnect the brake lines.
      GTY829586Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a From 1st Chamber of Brake Master Cylinder Sub-assembly
      *b From 2nd Chamber of Brake Master Cylinder Sub-assembly
      *c To Front Wheel Cylinder Assembly RH
      *d To Front Wheel Cylinder Assembly LH
      *e To Rear Wheel Cylinder Assembly RH
      *f To Rear Wheel Cylinder Assembly LH
    2. Using a union nut wrench, disconnect the front No. 3 brake tube from the front flexible hose.
      GTY466310Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Front Flexible Hose
      *2 Grommet
    3. Disengage the grommet.
    4. Using a union nut wrench, disconnect the front No. 3 brake tube from the brake actuator assembly.
      GTY825145Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disengage the clamp to remove the front No. 3 brake tube.
      NOTE:
      • Do not kink or damage the front No. 3 brake tube.
      • Do not allow any foreign matter such as dirt or dust to enter the front No. 3 brake tube from the connecting parts.
  11. REMOVE FRONT NO. 1 BRAKE TUBE 
    1. Using a union nut wrench, disconnect the front No. 1 brake tube from the brake actuator assembly.
      GTY825143Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the clamp to remove the front No. 1 brake tube.
      NOTE:
      • Do not kink or damage the front No. 1 brake tube.
      • Do not allow any foreign matter such as dirt or dust to enter the front No. 1 brake tube from the connecting parts.
  12. REMOVE REAR NO. 1 BRAKE TUBE 
    1. Using a union nut wrench, disconnect the rear No. 1 brake tube from the brake actuator assembly.
      GTY825142Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the clamp to remove the rear No. 1 brake tube.
      NOTE:
      • Do not kink or damage the rear No. 1 brake tube.
      • Do not allow any foreign matter such as dirt or dust to enter the rear No. 1 brake tube from the connecting parts.
  13. REMOVE BRAKE ACTUATOR WITH BRACKET 
    1. Release the lock lever and disconnect the connector from the brake actuator assembly.
      GTY794497Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Release the lock lever
      Disconnect the connector
      NOTE:

      Be careful not to allow any brake fluid to enter the connector.

    2. Using a union nut wrench, disconnect the 3 brake lines from the brake actuator assembly.
      GTY825139Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 bolts, nut and brake actuator with bracket.
      GTY825137Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not damage the brake lines.
      • Do not hold the brake actuator assembly by the connector.

      HINT: 

      Remove the brake actuator with bracket while avoiding the brake lines.

  14. REMOVE NO. 5 BRAKE ACTUATOR BRACKET 
    1. Remove the bolt and No. 5 brake actuator bracket.
      GTY816618Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE BRAKE ACTUATOR ASSEMBLY 
    1. Remove the 3 bolts and brake actuator assembly from the brake actuator bracket assembly.
      GTY836387Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE BRAKE ACTUATOR BOLT CUSHION 
    1. Remove the 3 brake actuator case collars from the brake actuator bolt cushions.
      GTY803494Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Brake Actuator Case Collar
      *2 Brake Actuator Bolt Cushion
    2. Remove the 3 brake actuator bolt cushions from the brake actuator bracket assembly.
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