RUBBER CUP OF BRAKE MASTER CYLINDER REPLACEMENT
I. OPERATION FLOW CHART Check whether or not the vehicle has the affected vehicle VIN. Not Involved No further action required. Involved Check leakage of brake master with plate cylinder Leakage Detected No Leakage Replace the brake booster assembly. Replace the master cylinder cup. Campaign completed, return the vehicle to the customer. 1
II. IDENTIFICATION OF AFFECTED VEHICLES Vehicle Model WMI VDS VIN Range VIS Production Period GS BG9## 0001002 5029310 BH9## 0001004 5035649 CH9## 0001002 0015096 17 Sep, 2004 through 28 Feb, 2006 IS JTH BK2## 0001001 5007477 BE2## 0001001 5003834 CK2## 0001001 5003003 27 May, 2005 Through 20 Mar, 2006 BB2## 0001008 2000572 GA3## 0001010 0064276 RX JTJ 2T2 HF3## 0001020 2014509 HA3## 0001045-0103457 GA3## C001001 C053398 HA3## C001001 C109797 10 Feb, 2003 Through 18 Feb, 2006 Crown JTD BK8## 0028873 1021019 LTV BG8## 0030001 0056518 LTV BJ8## 0000001 0003131 8 Nov, 2004 Through 4 Jan, 2006 Reiz LTV BG2## 0002030 0002380 18 Oct, 2005 Through BJ2## 0000032 0013438 6 Jan, 2006 Avalon 4T1 BK3## U001003 U124198 Alphard JT7 11M## 0043208-0089690 DD2## 0073058 0139663 DP2## 0001001 0102288 17 Sep, 2004 Through 22 Feb, 2006 15 Dec, 2003 Through 29 Nov, 2005 Highlander JTE ED2## 0025894 0041931 EP2## 0001001 0153766 GD2## 0072942 0139662 30 May, 2003 Through 24 Nov, 2005 GP2## 0001006 0102287 HD2## 0025363 0042017 2
HP2## 0001023 0153742 NOTES: Check the VIN list to confirm the VIN is involved in this SSC. This will verify the vehicle is affected and has not already been completed prior to dealer shipment or by another dealer. III. PREPARATION A. TOOLS & EQUIPMENT Standard Hand Tools Torque Wrench Intelligent Tester Ⅱ Protective Eyewear Workbench with vise Special Service Tools (SST) o 09012-1C120 - Deep Socket Wrench 12 mm o 09012-1C130 - Deep Socket Wrench 14 mm o 09017-1C100 - Union Nut Wrench 10mm o 09072-1C100 - Convex Scale Master cylinder clip B. SUPPLIES Marking Pen Protective Tape Paper Towels TOYOTA DOT3 Brake Fluid MP Grease Lithium Soap Base Glycol Grease (Rubber Grease) Filler Plastic Bag Plastic Tube C. PARTS REPLACEMENT PARTS: Constitution Part Number Part Name Quantity 04000-33158 Brake Master Cylinder Cup Kit 1 1 - Brake Master Cylinder O-Ring 1 2 - Cylinder Cup 1 3 - Master Cylinder Clip 1 REPLACING BRAKE BOOSTER DUE TO FAILED LEAK INSPECTION: Model Part Number Part Name Qty 44610-30A20 Brake Booster Assembly 1 44610-30A30 1 GS 44610-30A40 1 44785-47010 Brake Booster Gasket 1 90468-15005 Clip 1 44610-53251 Brake Booster Assembly 1 44610-53281 1 IS 44610-53290 1 44610-53310 1 44785-47010 Brake Booster Gasket 1 3
RX Crown Reiz Avalon Alphard Highlander 90468-15005 Clip 1 44610-0E011 or Brake Booster Assembly 1 44610-48211 44610-48231 1 44610-48400 1 44610-48420 1 44785-10020 Brake Booster Gasket 1 90468-16142 Clip 1 17176-20010 Air Surge Tank to Intake Manifold Gasket 1 22271-20040 Intake Air Connector Gasket 1 90949-01D02 Brake Tube Clamp 4 1 44610-0N010 Brake Booster Assembly 1 44610-0P010 1 44785-47010 Brake Booster Gasket 1 90468-15005 Clip 1 44610-0N010 Brake Booster Assembly 1 44610-0P010 1 44785-47010 Brake Booster Gasket 1 90468-15005 Clip 1 44610-07121 Brake Booster Assembly 1 44785-07010 Brake Booster Gasket 1 90468-16035 Clip 1 44610-58011 Brake Booster Assembly 1 44610-58020 1 44785-32010 Brake Booster Gasket 1 90468-15005 Clip 1 44610-48261 Brake Booster Assembly 1 44610-48271 1 44785-16020 Brake Booster Gasket 1 90468-16142 Clip 1 17176-20010 Air Surge Tank to Intake Manifold Gasket 1 22271-20040 Intake Air Connector Gasket 1 4
IV. BACKGROUND Brake fluids contain polymers that act as lubricants for certain brake system components. If brake fluid is used that does not contain such polymers, or contain only small amounts, a part of the rubber seal (Brake Master Cylinder Cup) located at the rear end of the brake master cylinder may become dry, and the Brake Master Cylinder Cup may curl during movement of the piston. If this occurs, a small amount of the brake fluid could slowly leak from the Brake Master Cylinder Cup, resulting in illumination of the brake warning lamp. 5
V. WORK PROCEDURE A. TABLE OF CONTENTS A. TABLE OF CONTENTS B. VEHICLE INSPECTION C. PRECAUTIONS IN ENTIRE WORK D. GENERAL DESCRIPTION E. CHECK LEAKAGE OF BRAKE MASTER WITH PLATE CYLINDER F. REPLACE CYLINDER CUP B. VEHICLE INSPECTION 6
Visually inspect both the vehicle interior and exterior. Note any damage found during the visual inspection prior to beginning work. As you disassemble the vehicle you may encounter parts that are in need of replacement, which are not covered by this repair procedure. If this is the case, please take the time to inform the customer that these parts can be replaced with minimal labor cost. C. PRECAUTIONS IN ENTIRE WORK 1. HANDLING OF REPLACEMENT PARTS a) Removed parts shall be broken or marked and stored in replacement parts box etc. so as not to be assembled again in error. 2. DO NOT USE CLOTHS a) Do not use shop cloths or cloth gloves. or little pieces of thread may get into the master cylinder. b) Keep your hands clean during work in order to prevent foreign matters from getting into the master cylinder. 3. DO NOT USE TOOLS MADE OF METAL FOR BRAKE RUBBER PARTS a) Do not use a tool made of metal. or rubber parts or their mounting grooves may be damaged. 4. HANDLING OF BRAKE TUBES a) Do not deform or damage brake tubes when removal/installation. b) Do not make brake tubes twist, bend, or interfere with other tube when assembly. 5. PREVENTION OF FOREIGN MATTERS FROM GETTING INTO BRAKE SYSTEM a) When removal of parts in the brake system, take measures to prevent foreign matters from getting into the system, for example, fitting a cover etc. 6. HANDLING OF BRAKE FLUID a) Do not reuse brake fluid. Brake fluid which has absorbed moisture or mineral oil may lose significantly its quality or deteriorate rubber seals, resulting in a serious failure which causes an accident. b) If leakage or exudation of brake fluid is found, it must be repaired. c) Brake fluid damages paint. Do not make brake fluid adhere to any painted surface. If brake fluid adheres to a painted surface, immediately rinse off with water. d) Bleeding the air may cause brake fluid to spray outwards. Wear safety glasses when performing this action. D. GENERAL DESCRIPTION REMOVE BRAKE MASTER WITH PLATE CYLINDER 7
CHECK LEAKAGE OF BRAKE MASTER WITH PLATE CYLINDER No Leakage Leakage Detected REPLACE BRAKE BOOSTER ASSEMBLY REPLACE CYLINDER CUP OF BRAKE MASTER WITH PLATE CYLINDER INSTALL BRAKE MASTER WITH PLATE CYLINDER E. CHECK LEAKAGE OF BRAKE MASTER WITH PLATE CYLINDER 1. REMOVE THE BRAKE MASTER WITH PLATE CYLINDER (Refer to the repair manual) 2. LEAKAGE CHECK a) As shown in the figure, illuminate the inside of the brake booster with a flashlight etc. from direction A and check if brake fluid adheres with eyes. Criterion: No brake fluid droplet adheres to the rod retainer or the spring. (Refer to 8 for details.) 8
<Reference> A fluid leakage path from the master cylinder to the brake booster is shown below. 3. LEAKAGE CRITERION BRAKE BOOSTER PASSED LEAK INSPECTION RESPONSE 9
Replace cylinder cup inside master cylinder Slightly adhesion means silicon oil (clear) used for assembly of booster and then no problem BRAKE BOOSTER FAILED LEAK INSEPCTION RESPONSE Replace brake booster assembly and cylinder cup inside master cylinder Brake fluid droplet (yellow) means NG F. REPLACE CYLINDER CUP 10
1. DISCHARGE BRAKE FLUID INSIDE THE MASTER CYLINDER a) Remove the reservoir cap and discharge fluid inside the reservoir tank. b) Install the reservoir cap. c) Move the piston slowly for 2 complete strokes to discharge fluid inside the master cylinder. NOTE: Do not push strongly, or fluid may splash. 2. PROTECT THE MASTER CYLINDER a) Cover the master cylinder with a clean plastic bag as shown in the figure to prevent foreign matters from getting into the cylinder. 3. CLEAN THE WORK SECTION OF THE MASTER CYLINDER a) Clean off the section shown in the figure with a paper towel so as not to generate dust. 4. REMOVE THE PISTON a) Pull off straight the piston by hand. b) The piston is a precision part. Store the piston in a manner were it will not be damaged or become dirty. 5. REMOVE THE O-RING a) Remove the O-ring by hand. b) Cut the removed O-ring and store it in a replacement parts box. 11
c) Clean off the O-ring mounting groove with a paper towel so as not to generate dust. 6. REMOVE THE CYLINDER CUP a) Use the tip of the supplied binding band to remove the cylinder cup. One binding band can be used for only one vehicle. NOTES: If one binding band is used for more than one vehicle, elasticity of the band decreases resulting in loss of workability and in addition, debris may be generated and get into parts. Do not cut the binding band, or dust may be generated. (1) Clean off the binding band. (2) Curl up the binding band as shown in the figure for easy grip. (3) Insert the tip of the binding band onto the outside of the cylinder cup as shown below. 12
(4) Keep the binding band flat and insert farther sliding it along the circumference. (5) The cylinder cup is raised by the binding band and can be removed. (6) Remove the cylinder cup. Cut the removed cup seal and store it in a replacement parts box. NOTE: Do not clean the cup seal mounting groove, or foreign matters may adhere by contraries. 7. INSTALL THE CYLINDER CUP a) Apply lithium soap base glycol grease evenly to entire circumference of the NEW cylinder cup. Application quantity: approx. 0.5 g Extrusion out of the tube: approx. 0.2 in (5 mm) b) Install the cylinder cup by hand in the direction shown in the figure NOTE: Do not damage the lip of the cup seal. 13
c) Illuminate the cylinder cup adequately and check for proper installation over its entire circumference. NOTE: If the cylinder cup is installed reversely, replace the cup seal with a new one. 8. INSTALL THE O-RING a) Apply lithium soap base glycol grease to entire circumference of the NEW O-ring. b) Install the O-ring so as not to twist it. 9. INSTALL THE PISTON a) Clean off the piston with new brake fluid. 14
b) Apply lithium soap base glycol grease thickly to entire circumference of the piston top. c) Apply lithium soap base glycol grease thinly to entire circumference of the piston side from the top to the half. g Total application quantity for (b) and (c): approx. 0.5 Extrusion out of the tube: approx. 0.2 in (5 mm) d) Secure proper contact between the cylinder cup and the piston by the following steps. NOTE: Do not insert the piston fully with one push. Insert the piston straight until the ports align the edge of the cylinder. Turn the piston approx. 90 degrees both right and left 5 times. e) Lastly, inspect the assembly direction of the piston. Inspection Criteria:Port not visible f) Move the piston slowly for 2 complete strokes. g) Remove the protective plastic bag. 15
10. BLEED AIR FROM THE MASTER CYLINDER a) Fix the master cylinder on a vice using paper towels as shown in the figure. b) Pour new brake fluid into the reservoir tank. c) Push the piston slowly and hold the pushed state. NOTE: Do not push strongly, or fluid may splash. d) Plug the tube holes with fingers and return the piston slowly. NOTE: Do not empty the reservoir tank, or air is sucked into the master cylinder. e) Release the plugging fingers. Then push the piston slowly and hold the pushed state, and plug the tube holes with fingers and slowly return the piston repeatedly several times. BRAKE BOOSTER PASSED LEAK INSPECTION: 11. INSTALL THE BRAKE MASTER WITH PLATE CYLINDER (Refer to the repair manual) BRAKE BOOSTER FAILED LEAK INSEPCTION: 1. REMOVE THE BRAKE BOOSTER ASSEMBLY (Refer to the repair manual) 2. INSTALL THE NEW BRAKE BOOSTER ASSEMBLY (Refer to the repair manual) 3. INSTALL THE BRAKE MASTER WITH PLATE CYLINDER (Refer to the repair manual) VI. APPENDIX 16