Toyota 44610-02210 Booster Assembly, Brake

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To check the operation of a power brake booster, depress the brake pedal several times with the engine off and ensure there is no change in the pedal reserve distance. Then, depress the pedal and start the engine. If the pedal goes down slightly, the operation is normal. To check the airtightness of the booster, start the engine and turn it off after one or two minutes. Depress the brake pedal slowly several times. If the pedal depresses less each time, the booster is airtight. Alternatively, depress the brake pedal while the engine is running and stop the engine with the pedal depressed. If there is no change in the pedal reserve travel after holding the pedal for 30 seconds, the booster is airtight. If removal of the power brake booster is necessary, it should not be disassembled and requires special tools. Remove the brake master cylinder and air filter housing, disconnect the vacuum hose from the booster, and unclip or detach any brake lines around the booster. Locate the clevis which connects the booster pushrod to the top of the brake pedal and remove the clevis pin retaining clip with pliers. Remove the four nuts and washers holding the brake booster to the firewall and slide the booster straight out from the firewall until the studs clear the holes. Installation procedures are the reverse of removal, with the clevis locknut and booster mounting nuts tightened to the proper torque specifications. If a new power brake booster unit is being installed, the booster pushrod-to-master cylinder piston clearance must be at zero to avoid brake dragging or excessive pedal travel. Finally, adjust the brake pedal height and free play and bleed the system.

Start by depressing the brake pedal multiple times to perform an operating check on the power brake booster, making sure that there is no change in the pedal reserve distance with the engine off. Then, depress the pedal and start the engine and check if the pedal goes down slightly indicating normal operation. To check air tightness of booster, start engine and stop it after one or two minutes. After that try slowly depressing the brake pedal several times and notice whether there is less depression each time to show airtight seal. Besides, turn on the engine and press down on the brake pedal before turning off the ignition. If you hold this position for 30 seconds but there is no notable change in the pedal reserve travel indicator, then your booster is airtight. When removing them, however, power brake booster units should not be taken apart; instead they are to be replaced with a new or rebuilt one as their complexity makes them crucial to braking performance. Start by taking out the brake master cylinder and air cleaner housing. Next, disconnect a vacuum hose of a booster in an engine compartment. In any case where vehicle has cruise control system remove its actuator along with bracket. Avoid breaking any brake pipe about this booster when removing it carefully. Locate clevis attaching pushrod of booster into brake pedal then remove retaining clip from clevis pin and get out pin finally at last. Last but not least remove four nuts which support washer securing bulbous nose bonnet over firewall and slide it freely through studs until holes are not blocked by such devices anymore. Then follow removal procedures in reverse ensuring that locknut as well as mounting nuts for clevis are tightened according to specified torque values for installation purposes of course. Before fitting new power brake booster unit find out if rod clearance may cause dragging or excessive travel of brakes; take care about it using required sizes for adjustment so far as needed right now just as follows then! Finally, adjust braking height and pedal free play plus bleed this system after the completion of lastly installing brake hoses, lines, as well as master cylinder.