Brake Master Cylinder Components

Hold-down Clamp

Battery Tray

Battery Tray

w/o ABS

Master Cylinder

Brake Boosler

Check Valve \ Bracket \

Master Cylinder

Check Valve \ Bracket \

Switch Connector

Switch Connector

Grommei -

♦ Non-reusable part fj ^ Lithium soap base glycol grease

Grommei -

Cylinder Body

Reservoir

Cylinder Body

REMOVAL

1. REMOVE BATTERY

2. DISCONNECT LEVEL WARNING SWITCH CONNECTOR

3. DRAW OUT FLUID WITH SYRINGE NOTICE:

Do not let brake fluid remain on a painted surface. Wash it off immediately.

DISCONNECT RESERVOIR HOSE

2006 Toyota Hilux Brake Line Diagram

5. DISCONNECT BRAKE LINE

Using SST, disconnect the 5 brake lines from the master cylinder and 3-way union.

SST 09023-00100

Using SST, disconnect the 2 brake lines from the master cylinder.

SST 09023-00100

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6. REMOVE MASTER CYLINDER

(a) Remove the 2 mounding nuts. Torque: 13 N m (130 kgf cm, 9 ft lbf)

Pull out the check valve bracket, 3-way and master cylinder.

Pull out the check valve bracket and master cylinder.

(d) Remove the gasket from the master cylinder.

7. REMOVE RESERVOIR

(a) Pull out the reservoir stopper. HINT:

At the time of installation, make sure to insert the reservoir stopper through holes of the reservoir and the master cylinder groove.

(b) Remove the reservoir and 2 grommets.

(c) Remove the cap and strainer from the reservoir.

BR-12

INSTALLATION

Installation is in the reverse order of removal (See page BR-10).

HINT:

Before installation, adjust length of brake booster push rod (See page 8R-16).

After installation, fill the brake reservoir with brake fluid, bleed the brake system (See page BR-4), and check for leaks.

Check and adjust brake pedal (See page BR-6).

GOOD NO GOOD

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