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:

(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

Click here

6. BLEED MASTER CYLINDER

Click here

7. BLEED BRAKE LINE

Click here

8. BLEED BRAKE ACTUATOR

Click here

9. INSPECT FLUID LEVEL IN RESERVOIR

Click here

10. INSPECT FOR BRAKE FLUID LEAK

11. INSPECT BRAKE PEDAL HEIGHT

Click here

12. INSPECT PEDAL FREE PLAY

Click here

13. INSPECT PEDAL RESERVE DISTANCE

Click here