Scion 2005-06

Actuator

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Removal & Installation



  1. Use a syringe to drain the brake fluid from the reservoir.
    WARNING
    Clean, high quality brake fluid is essential to the safe and proper operation of the brake system. You should always buy the highest quality brake fluid that is available. If the brake fluid becomes contaminated, drain and flush the system, then refill the master cylinder with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded. Also, do not allow any brake fluid to come in contact with a painted surface; it will damage the paint.

  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. If necessary, disconnect the positive battery cable, then remove the battery.
  6.  
  7. Remove brake actuator with bracket, as follows:
    1. Release the latch of the actuator connector to disconnect the connector.
    2.  
    3. Tag the installed locations of the brake lines to the actuator.
    4.  
    5. Using SST 09023-00101, or equivalent brake line tool, disconnect the 6 brake tubes from the brake actuator.
    6.  
    7. Remove the 3 bolts and brake actuator with bracket.
    8.  

  8.  
  9. Remove the nut, 2 bolts and brake actuator from the brake actuator bracket.
  10.  

To install:

  1. Install the brake actuator with the 2 nuts to the brake actuator bracket and tighten to 48 inch lbs. (5.4 Nm).
  2.  
  3. Install brake actuator with bracket, as follows:
    1. Install the brake actuator with bracket with the 3 bolts and tighten to 14 ft. lbs. (19 Nm).
    2.  
    3. Using the brake line tool, connect the 6 brake tubes to the correct positions of brake actuator, as shown in the illustration. Tighten the lines to 11 ft. lbs. (15 Nm).

      Click image to see an enlarged view

      Fig. Brake line identification

    4.  
    5. Connect the brake actuator connector.
    6.  

  4.  
  5. Install battery and connect the positive cable, if disconnected.
  6.  
  7. Connect the negative battery cable.
  8.  
  9. Fill the reservoir with brake fluid, then bleed the brake system, as outlined in this section.
  10.  
  11. Check the fluid level in reservoir and add if necessary.
  12.  
  13. Check for any brake fluid leakage.
  14.  

  1. Use a syringe to drain the brake fluid from the reservoir.
    WARNING
    Clean, high quality brake fluid is essential to the safe and proper operation of the brake system. You should always buy the highest quality brake fluid that is available. If the brake fluid becomes contaminated, drain and flush the system, then refill the master cylinder with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded. Also, do not allow any brake fluid to come in contact with a painted surface; it will damage the paint.

  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the right front wheel.
  6.  
  7. Remove hood to front end panel seal.
  8.  
  9. Remove the front fender liners.
  10.  
  11. Remove front bumper cover.
  12.  
  13. Remove the left headlamp assembly.
  14.  
  15. Remove brake actuator with bracket, as follows:
    1. Disconnect the actuator connector.
    2.  

  16.  
  17. Tag the installed location of the brake lines.
    1. Using SST 09023-00101 or equivalent brake line tool, disconnect the 6 brake tubes from the actuator with the bracket.
    2.  
    3. Remove the 2 bolts, nut and the actuator with bracket.
      WARNING
      Be careful not to damage the brake tubes and wire harness.

    4.  

  18.  
  19. Remove the 2 nuts and the brake actuator assembly from the brake actuator bracket.
  20.  

To install:

  1. Install the brake actuator assembly with the 2 nuts and tighten to 48 inch lbs. (5.4 Nm).
  2.  
  3. Install brake actuator with bracket:
    1. Install the actuator with bracket, the 2 bolts and nut and tighten to 14 ft. lbs. (19 Nm).
      NOTE
      Be careful not to damage the brake tubes and wire harness. Tighten the bolts and nut in order from 1 to 3.

    2.  
    3. Connect the actuator connector.
      NOTE
      Make sure that the lever is locked securely.

    4.  
    5. Using the brake line tool, connect each brake tube to the actuator with the bracket, as shown in the illustration. Tighten to 11 ft. lbs. (15 Nm).

      Click image to see an enlarged view

      Fig. Brake line identification

    6.  

  4.  
  5. Install the headlamp.
  6.  
  7. Install the front bumper cover.
  8.  
  9. Install the front fender liners.
  10.  
  11. Install the hood to front end panel seal
  12.  
  13. Install the right front wheel.
  14.  
  15. Fill the reservoir with brake fluid, then bleed the brake system, as outlined in this section.
  16.  
  17. Check the fluid level in reservoir and add if necessary.
  18.  
  19. Check for any brake fluid leakage.
  20.  
  21. Check and adjust the aim of the headlights.
  22.  

 
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