Brake Booster

REMOVAL

Remove the parts in the numerical order shown in the figure.

Land Cruiser Engine
Fig. 9-63
Take out the fluid with a syrige or such.

Disconnect the brake tube with SST SST [09751-36011]

Do not allow any brake fluid to get on painted surfaces.

Disconnect the brake tube with SST SST [09751-36011]

Do not allow any brake fluid to get on painted surfaces.

DISASSEMBLY

Disassemble the parts in the numerical order shown in the figure.

Brake Fluid Cruiser

1. Push Rod

2. Clevis

3. Boot

4. Lock & Body Connector

5. Air Filter Element

6. Rear Body with Diaphragm Plate

7. Spring

8. Front Body

9. Rear Body

10. Reaction Retainer, Lever & Plate

11. Snap Ring & Plate

12. Operating Rod

1 3. Diaphragm & Retainer

14 Diaphragm Plate

Matchmarks

01. Place matchmarks on the front body and rear body.

2. Pry out the lock with a screwdriver.

Set the booster to the SST. SST (09753-00010) of set [09738-00020] Tightening torque: 1.1 - 1.3 kg-m (8-9 ft-lb)

Tighten the left and right nuts uniformly.

0 Remove the body connector by turning it counterclockwise with a screwdriver.

Remove the snap ring and plate with snap ring pliers.

Cruiser Inspection Plates

Pry out the circular ring with a screw driver and pull out the air valve together with the air filter elements.

Remove the diaphragm retainer with SST. SST [09736-30020]

INSPECTION & REPAIR

Inspect the disassembled parts on the following points and repair or replace if necessary.

Diaphragm & Booster Piston

Inspect the diaphragm and booster piston for wear, damage or cracks.

Booster Air Valve & Piston Rod

Inspect for wear, damage or bending.

Toyota Sequoia Brake Booster Seal

Booster Body, Seal & Bearing

Inspect the booster bodies, seal and bearing for wear or damage.

Cruiser Inspection Plates

Replace The Seal

1. Remove the seal from the shell by prying.

2. Install a new seal.

Vacuum Check Valve

Check the operation of the valve.

ASSEMBLY

Assemble the parts in the numerical order shown in the figure.

12 13

Cruiser Brake Booster Check ValveDiaphragm 2002 Corolla

1 Diaphragm Plate

2. Diaphragm & Retainer

3. Operating Rod

4. Snap Ring & Plate

5. Reaction Retainer, Lever & Plate 6 Rear Body

7. Front Body

8 Spring

9. Rear Body with Diaphragm Plate

10. Lock & Body Connector

11. Air Filter Element

12. Boot

13. Clevis

14. Push Rod

Before assembly, coat the parts shown below with silicon grease (furnished in repair kit).

Before assembly, coat the parts shown below with silicon grease (furnished in repair kit).

Brake Booster Push Rod Grease

1. Rod Seal Lip

2. Push Rod Perimeter

3. Operating Rod

4. Bearing, Valve body Seal Lip

5. Diaphragm Plate Inside & Outside

6. Diaphragm to Shell Contacting Surface

1. Rod Seal Lip

2. Push Rod Perimeter

3. Operating Rod

4. Bearing, Valve body Seal Lip

5. Diaphragm Plate Inside & Outside

6. Diaphragm to Shell Contacting Surface

0 Install the retainer by turning the SST about 45°.

SST [09736-30020]

Install the snap ring onto the air valve.

Reaction Levers Booster

0 Install the reaction levers and plate with its protrusion directed upward.

Fig. 9-83

%

V->. ' . 1

jflrngjigS^

Y/ ^^^^^^^

Face the body connector in the direction I \ shown in the figure.

1881

Reaction Levers Booster

Set the booster to SST. SST (09753-00010) of set [09738-00020] Tightening torque: 1.1 - 1.3 kg-m (8-9 ft-lb)

1. Align the matchmarks on the body.

2. Tighten the left and right nuts evenly.

0Turn the body connector clockwise with a screwdriver.

DISASSEMBLY

Disassemble the parts in the numerical order shown in the figure.

9-89

9-89

Exploded Drawing Car
4 Fig. 9-87
1 3 Fig 9-91

1.

Push Rod

9

Rear Body

2

Clevis

10.

No.2 Reaction, No. 1 Retainer,

3

Boot

Plate & Lever

4

Air Filter Element

11

Snap Ring

5.

Booster Band

12.

Operating Rod

6

Rear Body with Diaphragm Plate

13.

Diaphragm & Retainer

7

Spring

14

Diaphragm Plate

8

Front Body

15.

Piston Bearing & Circular Internal Ring

Remove the retainer and filter elements with a screwdriver.

A Place matchmarks on the front and rear body, and fix to the SST.

SST (09753-00010) of set [09738-00020]

Internal Plate Diaphragm
Fig. 9-88
Cruiser Inspection Plates
Fig. 9-92

Remove the diaphragm and the diaphragm plate with SST. SST [09736-30020]

Remove the diaphragm and the diaphragm plate with SST. SST [09736-30020]

INSPECTION & REPAIR

Inspect the disassembled parts on the following points, and repair or replace parts if necessary.

Vacuum Diaphragm Diff Lock Toyota

Diaphragm & Diaphragm Plate

Inspect the diaphragm and diaphragm plate for wear, damage or cracks.

Valve Operating Rod

Inspect the valve operating rod for wear or damage.

Cruiser Inspection Plates
II»

Body & Body Seal

Inspect the seals for wear or damage.

Replace The Seal

Remove the seal from the shell. Install the new seal.

Replace The Bearing

Remove the bearing from the shell and install a new bearing.

Vacuum Check Valve

Check the operation of the valve.

ASSEMBLY

Assemble the parts in numerical order shown in the figure.

9-105

9-105

1 1 Fig. 9-106
Snap Valve Spring Retainer Installer

5 Fig 9-103

2 Fig 9-100 9-101

5 Fig 9-103

2 Fig 9-100 9-101

1 Diaphragm Plate

2 Diaphragm & Retainer

3 Operating Rod

4 Snap Ring & Plate

5 Reaction Retainer. Lever & Plate

6 Rear Body

7 Front Body

8. Spring

9 Rear Body with Diaphragm Plate

10. Lock & Body Connector

11. Air Filter Element

12 Boot

13 Clevis

1 4 Push Rod

Fig. 9-100

Before assembly, coat the parts shown below with silicon grease (furnished in repair kit). 1 6

Booster Rod Seal

1. Rod Seal Lip & Perimeter

2. Push Rod

3. Operating Rod & Seal

4. Bearing, Valve Body Seal Lip

5. Diaphragm Plate Inside & Outside

6. Diaphragm to Shell Contacting Surface & to Retainer Contacting Surface

Fig. 9-101

Toyota 09736 30020

Fig. 9-102

Install the retainer by turning about 45° with SST.

SST [09736-30020]

Fig. 9-102

Install the plate and snap ring onto the valve operating rod.

Fig. 9-103

Fig. 9-103

Brake Booster Operating Rod Assembly

0 Install the reaction levers and plate with its protrusion directed upward.

Fig. 9-104

Fig. 9-104

Align the matchmarks and fix to the SST. SST (09753-00010) of set [09738-00020]

Fig. 9-105

Fig. 9-105

SST (09753-00010) of set [09738-00020]

Fig. 9-106

Install the air filter elements and retainer

DISASSEMBLY

Disassemble the parts in the numerical order shown in the figure.

Fig. 9-107

Disassembling Truck Brake Drum

1.

Clevis

9.

Air Cleaner Element & Separater

2.

No. 2 Body

10.

Rear Diaphragm & Piston Plate

3.

No. 1 Body

11.

Valve Stopper Key

4.

Piston Return Spring

12.

No.1 Piston

5.

Piston Rod

13.

Air Vlave Operating Rod

6.

No. 3 Body

14.

No. 3 Body

7.

Deflector

15.

No. 2 Piston & Front Diaphragm

8.

Air Cleaner Element & Boot

16.

Reaction Disc, Case & Oil Seal

Disassemble the parts in the numerical order shown in the figure.

Fig. 9-108

Air Filter For Toyota Land Cruiser

1. Clevis

4 Piston Return Spring

5. Piston Rod

7 E Ring

8 Air Cleaner & Boot

9. Air Cleaner Element & Separater

10 Rear Diaphragm & Piston Plate

11. Valve Stopper Key

12 No. 1 Piston

13. Air Valve Operating Rod

14. Clip &'Retainer

15 No.3 Body

16 No.2 Piston & Front Diaphragm

17 Reaction Disc, Case & Oil Seal

Fig. 9-109

Fig. 9-109

Brake Booster Reaction Disc

Disconnect the body.

1. Place matchmarks on the No.1 and No.2 body.

2. Install the booster to the SST and tighten the nut.

SST [09738-00020]

Tightening torque:

Tighten the right and left nuts evenly.

3. Turn the joint handle of the SST to separate No.1 body and No.2 body.

SST [09738-00020]

Fig. 9-111

Fig. 9-112

^SST

JPLl

JPLl

With the valve operating rod facing downward, No.2 body and remove the No.3 body.

Disassemble the No.3 body. 1. Clamp SST in a vise and insert the No.3 body into it. SST [09738-00020]

Fig. 9-113

Fig. 9-114

AISIN & JKC

AISIN TYPE

AISIN & JKC

AISIN TYPE

Brake Booster Aisin
Fig. 9-115
Fig. 9-116

Reaction Disc

^-71

a

1

Lj

4. Remove the No.3 body.

3. Push in the valve operating rod, pull out the valve stopper key and remove the piston No.1.

Remove the reaction disc from the case.

2. Of the 4ribs, push in two diagonal ones with your finger and turn the piston plate counterclockwise.

Then remove the diaphragm and piston plate.

3. Push in the valve operating rod, pull out the valve stopper key and remove the piston No.1.

4. Remove the No.3 body.

Remove the reaction disc from the case.

Fig. 9-117 AISIN TYPE

INSPECTION & REPAIR

Rear Diaphragm & Plate

Inspect for wear, damage or cracks.

INSPECTION & REPAIR

Rear Diaphragm & Plate

Inspect for wear, damage or cracks.

JKC TYPE

Fig. 9-118 AISIN TYPE

Front Diaphragm & No.2 Piston

Inspect the diaphragm No.2 piston and oil seal for wear, damage or cracks.

JKC TYPE

JKC TYPE

Fig. 9-119

SST

-SST

Cruiser Inspection Plates
SST

-SST

Fig. 9-121

-SST

Fig. 9-121

SiMicoh^ Grease

2. Apply silicon grease onto the seal and install them into the No.3 Body

Replace The Seal & Bearing

AISIN TYPE

1. Remove the seal and bearing from the No.3 body with SST. SST [09726-35010] No.1 [09753-30020] [09608-20011] No.2

2. Install the seal and bearing to the No.3 body with SST. SST [09726-35010] No.1 [09753-30020]

1. Coat the outside of the oil seal with silicon grease.

2. Be careful not to crack the bearing during assembly.

Replace The Seal & Bearing

JKC TYPE

1. Remove the circular ring and seal from the No.3 body.

2. Apply silicon grease onto the seal and install them into the No.3 Body

Fig. 9-123

Install a circular ring into the No.2 piston.

Fig. 9-123

Fig. 9-124 AISIN TYPE

Fig. 9-124 AISIN TYPE

Piston Rod

Inspect for wear, damage or bend.

JKC TYPE

Fig. 9-125

Booster Piston

Inspect for scratches, cracks or deformation.

Fig. 9-126 AISIN TYPE

Air Valve Operating Rod

Inspect for wear or damage.

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