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Brake Actuator: Removal

NOTE: If brake fluid spills on any painted surface, wash or otherwise remove it completely.
  1. PERFORM ACCUMULATOR ZERO DOWN  (See BLEEDING )
  2. REMOVE ABS MOTOR RELAY 
    1. Remove the 2 ABS motor relays with the ignition switch off in order to disable brake control.
    NOTE: If the pump motor operates while air remains inside the brake reservoir tube No.1 hose, air will enter the actuator, and this will make bleeding the brakes more difficult.
    NOTE: After the brake actuator assembly has been replaced, remove the ABS motor relay before bleeding the brakes.
    Fig 1: Locating ABS Motor Relay
    G05202789Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
  3. DRAIN BRAKE FLUID 
  4. REMOVE FRONT FENDER TO COWL SIDE SEAL RH 
  5. REMOVE FRONT FENDER TO COWL SIDE SEAL LH 
  6. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH  (See REMOVAL )
  7. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH  (See REMOVAL )
  8. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY  (See REMOVAL )
  9. REMOVE WIND SHIELD WIPER MOTOR ASSEMBLY  (See REMOVAL )
  10. REMOVE COWL PANEL SUB-ASSEMBLY  (See REMOVAL )
  11. REMOVE BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY 
    1. Disconnect the warning switch connector.
    2. Separate the brake actuator hose from the clamp.
    3. Remove the 2 clips and brake actuator hose.
      Fig 2: Identifying Warning Switch Connector, Clips And Brake Actuator Hose
      G05276948Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    4. Remove the 2 clips and 2 reservoir tubes from the brake master cylinder reservoir assembly.
      Fig 3: Locating Clips And Reservoir Tubes From Brake Master Cylinder Reservoir Assembly
      G05276949Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    5. Remove the 2 bolts and the brake master cylinder reservoir assembly.
      6. Fig 4: Locating Brake Master Cylinder Reservoir Assembly Bolts
      G05202792Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
  12. REMOVE FRONT WHEEL RH 
  13. REMOVE BRAKE ACTUATOR ASSEMBLY WITH BRAKE ACTUATOR BRACKET ASSEMBLY 
    1. Remove the bolt and the brake actuator bracket No. 7 with clamp.
      Fig 5: Locating Brake Actuator Bracket No.7 With Clamp And Bolt
      G05276951Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    2. Using SST, disconnect the 6 brake tubes from the actuator assembly with brake actuator bracket assembly.

      SST 09023-00101 

      Fig 6: Locating Brake Tubes From Actuator Assembly With Brake Actuator Bracket Assembly
      G05276952Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    3. Use tags or make a memo to identify the places to reconnect.
      Fig 7: Identifying Brake Tubes Assembly Pipes Position
      G05276953Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    4. Using SST, disconnect the front brake No. 8 tube.

      SST 09023-00101 

      Fig 8: Disconnecting Front Brake No.8 Tube
      G05276954Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    5. Release the lock lever and disconnect the actuator connector.
      6. Fig 9: Releasing Lock Lever And Disconnect Actuator Connector
      G05276955Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    6. Remove the bolt from the brake tube bracket.
    7. Remove the 3 nuts and brake actuator assembly with brake actuator bracket assembly.
    NOTE: Do not damage the brake tubes.
    Fig 10: Locating Nuts And Brake Actuator Assembly
    G05202798Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
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