Toyota Pick-ups/Land Cruiser/4Runner 1989-1996

Power Brake Booster

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REMOVAL & INSTALLATION



See Figures 1, 2 and 3

  1. Remove the master cylinder.
  2.  
  3. At the brake pedal, remove the clip and separate the clevis from the pedal.
  4.  
  5. Remove the pedal return spring.
  6.  
  7. Disconnect the vacuum hose from the booster.
  8.  
  9. Loosen the four nuts, then pull out the vacuum booster, bracket and gasket.
  10.  

To install:

Some models employ a spacer and additional gaskets at the firewall.

  1. Using a new gasket, install the booster, then tighten the mounting bolts to 9 ft. lbs. (13 Nm).
  2.  
  3. Install the clevis pin to the clevis through the brake pedal. Secure the pin with the clip.
  4.  
  5. Install the pedal return spring.
  6.  

  1. Adjust the length of the booster pushrod as follows:
    1. Install the gasket to the master cylinder.
    2.  
    3. Set the SST 09737-00010 or equivalent on the gasket, then lower the pin until its tip slightly touches the piston.
    4.  
    5. Turn the tool upside down and position it on the booster.
    6.  
    7. Measure the clearance between the booster pushrod and the pin head. It should be null.
    8.  
    9. Adjust the booster pushrod length until the pushrod lightly touches the pin head. While doing this depress the brake pedal enough so that the pushrod sticks out.
    10.  

  2.  
  3. Install the master cylinder.
  4.  
  5. Attach the vacuum hose to the booster.
  6.  
  7. Fill the reservoir with brake fluid, then bleed the system.
  8.  
  9. Check for leakage.
  10.  
  11. Check and adjust the brake pedal.
  12.  



Click image to see an enlarged view

Fig. Fig. 1: Slide the pin through the clevis, then secure it with the clip



Click image to see an enlarged view

Fig. Fig. 2: Install the tool on top of the gasket as shown



Click image to see an enlarged view

Fig. Fig. 3: Set the tool on the gasket, then lower the pin until its tip slightly touches the piston

 
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