Toyota Tacoma 2015-2018 Service Manual: Reassembly

REASSEMBLY

PROCEDURE

1. INSTALL BRAKE BOOSTER ACCUMULATOR ASSEMBLY

(a) Place the brake booster pump in a vise with a cloth.

(b) Install the brake booster accumulator pipe, compression spring and a new O-ring.

NOTICE:

Ensure that no foreign matter enters the pump.

(c) Using a socket wrench (17 mm), install the brake booster accumulator onto the brake booster pump.

Torque:

57 N·m {585 kgf·cm, 42 ft·lbf}

2. INSTALL MASTER CYLINDER SOLENOID

(a) Place a new gasket on the master cylinder solenoid and install them onto the master cylinder body with 6 new bolts.

Torque:

32 N·m {325 kgf·cm, 24 ft·lbf}

NOTICE:

Do not let water, dust, and/or other objects attach to the surface and/or attaching surface of the master cylinder solenoid, master cylinder and body gasket.

3. INSTALL PISTON

(a) Apply lithium soap base glycol grease to the new piston.

(b) Install the piston onto the master cylinder body.

(c) Using 2 screwdrivers, install a new C-ring while pressing the piston. NOTICE: If the piston is pulled out at an angle, there is a possibility that the cylinder bore could be damaged. Be careful not to damage the rubber lips on the piston when reassembling.

4. INSTALL MASTER CYLINDER BOOT

5. INSTALL MASTER CYLINDER PUSH ROD CLEVIS

(a) Install the lock nut and master cylinder push rod clevis onto the rod operating adapter.

(b) Install the hydraulic brake booster side lock nut and rod operating adapter onto the hydraulic brake booster.

Torque:

26 N·m {260 kgf·cm, 19 ft·lbf}

6. INSTALL BRAKE BOOSTER PUMP BRACKET

(a) Using a hexagon wrench (5 mm), install the brake booster pump bracket with the 2 screws.

Torque:

7.8 N·m {80 kgf·cm, 69 in·lbf}

(b) Install the bush onto the brake booster pump bracket.

7. INSTALL BRAKE ACTUATOR BRACKET

(a) Using a hexagon wrench (5 mm), install the brake actuator bracket with the screw.

Torque:

7.8 N·m {80 kgf·cm, 69 in·lbf}

8. INSTALL BRAKE BOOSTER WITH ACCUMULATOR PUMP ASSEMBLY

(a) Install the 2 collars and 2 bushes onto the brake booster w/ accumulator pump assembly.

(b) Using a hexagon wrench (4 mm), install the 2 pins.

Torque:

7.8 N·m {80 kgf·cm, 69 in·lbf}

(c) Install the brake booster w/ accumulator pump assembly.

(d) Install a new clip.

(e) Install the wire harness with the 2 screws. Torque: 2.9 N·m {30 kgf·cm, 26 in·lbf}

(f) Install the 2 new plugs.

9. INSTALL BRAKE ACTUATOR TUBE NO. 1

(a) Using a union nut wrench, install the brake actuator tube No. 1.

Torque:

without union nut wrench :

15 N·m {155 kgf·cm, 11 ft·lbf}

with union nut wrench :

14 N·m {145 kgf·cm, 10 ft·lbf}

10. INSTALL BRAKE ACTUATOR HOSE NO.1

(a) Using needle-nose pliers, install the brake actuator hose and 2 clips.

11. INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY

(a) Install the cap.

(b) Apply lithium soap base glycol grease to the 3 new grommets.

(c) Install the 3 grommets to the master cylinder body.

NOTICE:

Be careful of the size of each grommets.

(d) Install the master cylinder reservoir.

(e) Using a pin punch and hammer, install a new pin onto the master cylinder reservoir.

(f) Install the screw onto the master cylinder reservoir. Torque: 1.7 N·m {17 kgf·cm, 15 in·lbf}

12. INSTALL BRAKE ACTUATOR BRACKET NO. 1

(a) Install the fluid level warning switch connector.

(b) Using a hexagon wrench (5 mm), install the brake actuator bracket No. 1 with the screw.

Torque:

7.8 N·m {80 kgf·cm, 69 in·lbf}