Toyota Tacoma manuals

Toyota Tacoma 2015-2018 Service Manual: Installation

INSTALLATION

PROCEDURE

1. INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD

NOTICE:

The brake booster interior must not be a vacuum when adjusting the booster. Stop the engine and depress the brake pedal several times until there is no vacuum in the booster.

HINT:

Adjust the booster push rod when the master cylinder sub-assembly is replaced with a new one. Adjustment is not necessary when the master cylinder sub-assembly is reinstalled and the booster is replaced with a new one.

(a) Apply chalk to the tip of an accessory tool.

HINT:

The accessory tool is enclosed with a new brake master cylinder sub-assembly.

(b) Place the accessory tool on the brake booster assembly.

(c) Measure the clearance between the brake booster push rod and accessory tool.

Standard clearance:

0 mm (0 in.)

HINT:

Adjust the clearance in the following cases:

  • If there is a clearance between the accessory tool and the shell of the brake booster (floating accessory tool), 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.

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

SST: 09737-00020

HINT:

Check the push rod clearance again after adjustment.

2. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY

(a) Install a new O-ring onto the brake master cylinder sub-assembly.

(b) Install the brake master cylinder sub-assembly with the 2 nuts onto the brake booster.

Torque:

13 N·m {127 kgf·cm, 9 ft·lbf}

(c) Using a union nut wrench, connect the 2 brake lines to the brake master cylinder sub-assembly.

Torque:

without union nut wrench :

20 N·m {199 kgf·cm, 14 ft·lbf}

with union nut wrench :

18 N·m {187 kgf·cm, 13 ft·lbf}

HINT:

  • This torque value can be obtained by using a torque wrench with a fulcrum length of 300 mm (11.8 in.) and a union nut wrench with a fulcrum length of 20 mm (0.787 in.).

    Click here

  • This torque value is effective when the union nut wrench is parallel to the torque wrench.

(d) Connect the brake fluid level warning switch connector to the brake master cylinder sub-assembly.

3. INSTALL CLUTCH RESERVOIR TUBE (for Manual Transmission)

(a) Connect the clutch reservoir tube to the reservoir.

4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Torque:

5.4 N·m {55 kgf·cm, 48 in·lbf}

NOTICE:

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

Click here 5. FILL RESERVOIR WITH BRAKE FLUID

5. FILL RESERVOIR WITH BRAKE FLUID

Click here 6. BLEED MASTER CYLINDER

6. BLEED MASTER CYLINDER

Click here 7. BLEED BRAKE LINE

7. BLEED BRAKE LINE

Click here 8. BLEED BRAKE ACTUATOR

8. BLEED BRAKE ACTUATOR

Click here 9. INSPECT FLUID LEVEL IN RESERVOIR

9. INSPECT FLUID LEVEL IN RESERVOIR

Click here 10. INSPECT FOR BRAKE FLUID LEAK

10. INSPECT FOR BRAKE FLUID LEAK

11. INSPECT BRAKE PEDAL HEIGHT

Click here 12. INSPECT PEDAL FREE PLAY

12. INSPECT PEDAL FREE PLAY

Click here 13. INSPECT PEDAL RESERVE DISTANCE

13. INSPECT PEDAL RESERVE DISTANCE

Click here Reassembly

Removal
REMOVAL CAUTION / NOTICE / HINT NOTICE: Release the vacuum from booster by depressing the brake pedal several times. Then remove the brake master cylinder from brake booster. PROCEDURE 1. PRECAU ...

Reassembly
REASSEMBLY PROCEDURE 1. INSTALL MASTER CYLINDER RESERVOIR GROMMET (a) Apply lithium soap base glycol grease to 2 new grommets. (b) Install the 2 grommets onto the brake master cylinder reservoir. ...

Other materials:

Precaution
PRECAUTION 1. IGNITION SWITCH EXPRESSIONS (a) The type of ignition switch used on this model differs according to the specifications of the vehicle. The expressions listed in the table below are used in this section. Expression Ignition Switch (Position) Engine ...

Removal
REMOVAL CAUTION / NOTICE / HINT CAUTION: Some of these service operations affect the SRS. Read the precautionary notices concerning the SRS before servicing. Click here PROCEDURE 1. PRECAUTION NOTICE: After turning the ignition switch off, waiting time may be required before disconnectin ...

Data List / Active Test
DATA LIST / ACTIVE TEST NOTICE: In the table below, the values listed under "Normal Condition" are reference values. Do not depend solely on these reference values when deciding whether a part is faulty or not. HINT: Using the Techstream to read the Data List allows the values or s ...

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