Brake Master Cylinder: Reassembly

1. Check the inside of the master cylinder for scratch.

If necessary, replace the master cylinder.

1. Place aluminum plates between the vise and master cylinder. Place the master cylinder in a vise.
2. Apply lithium soap base glycol grease to the rubber part as shown in the illustration.
3. Install the No. 1 and No. 2 pistons to the master cylinder body.
   Fig 1: Identifying No. 1 And No. 2 Pistons To Master Cylinder Body

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   • Install the pistons straight carefully not to give any damage to the inside of the cylinder.
   • Do not damage the lip of the cylinder cup.
4. Push in the piston and install a new gasket and a new piston stopper bolt.

   Torque: 10 N.m (102 kgf.cm, 7 ft.lbf) 

   Fig 2: Installing Piston Stopper Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using snap ring pliers, install the hole snap ring with the piston pushed in.
   NOTE: Do not scratch the inside of the cylinder body.
6. Apply lithium soap base glycol grease to a new O-ring.
7. Install the O-ring to the master cylinder body.

Fig 3: Removing Snap Ring

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply lithium soap base glycol grease and silicon grease to the 2 grommets as shown in the illustration.
2. Install the 2 grommets to the master cylinder body.
   Fig 4: Identifying Master Cylinder Union

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the master cylinder union with the stopper screw.

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

   SST 09737-00013 

2. Apply chalk to the flat tip of the SST rod. Turn the SST upside down and measure the clearance between the brake booster push rod and the SST.
   Fig 5: Adjusting Brake Booster Push Rod

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Clearance: 0 mm (0 in.) 

   If there is a clearance between the SST main body and the shell of the brake booster, the push rod is protruding too far.

   If the chalk does not stick on the tip of the brake booster push rod, the push rod protrusion is insufficient.

3. If the clearance is not within the standard, 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 

   Fig 6: Adjusting Push Rod Length

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT:

   Check the push rod clearance again after adjustment.