Toyota Tercel 1984-1994 Repair Guide

Power Brake Booster

Print

REMOVAL & INSTALLATION



See Figures 1, 2 and 3

  1. Disconnect the negative battery cable.
  2.  
  3. Remove any components necessary to gain working access.
  4.  
  5. Remove the brake master cylinder from the booster. Refer to the necessary service procedures.
  6.  



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the power brake booster mounting



Click image to see an enlarged view

Fig. Fig. 2: Brake lines and other components may have to be repositioned to gain access for removal of the brake booster



Click image to see an enlarged view

Fig. Fig. 3: After the clevis has been disconnected from the brake pedal, the attaching nuts can be removed

  1. Remove the vacuum hose from the booster.
  2.  
  3. From inside the car, disconnect the pedal return spring, clevis pin clip and pin.
  4.  
  5. Remove the brake booster retaining nuts. It will be helpful to have an assistant support the booster while the nuts are loosened.
  6.  
  7. Remove the booster from the engine compartment.
  8.  

To install:
  1. Have an assistant hold the booster in position while you install the retaining nuts. Tighten the nuts to 9 ft. lbs. (13 Nm).
  2.  
  3. Install the clevis pin and clip, then install the pedal return spring.
  4.  
  5. Connect the vacuum hose to the booster.
  6.  
  7. Install any other components necessary.
  8.  
  9. Adjust the pushrod length.
  10.  
  11. Install the master cylinder.
  12.  
  13. Adjust the brake pedal.
  14.  
  15. Bleed the brake system. Refer to the necessary service procedure.
  16.  

ADJUSTMENTS



See Figures 4 and 5

  1. Install the gasket on the master cylinder.
  2.  
  3. Set SST 09737-00010 or an equivalent gauging tool on the gasket, then lower the pin until it's tip slightly touches the piston.
  4.  
  5. Turn the tool upside down and set it on the booster.
  6.  
  7. Measure the clearance between the booster pushrod and the pin head. There should be no clearance. Adjust the pushrod length until the pushrod slightly touches the pin head.
  8.  



Click image to see an enlarged view

Fig. Fig. 4: Setting the adjustment tool on the master cylinder



Click image to see an enlarged view

Fig. Fig. 5: There should be no clearance between the tool and the pushrod. Adjust, as necessary

 
label.common.footer.alt.autozoneLogo