Toyota 44610-20800 Booster Assembly, Brake

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To perform an operating check, depress the brake pedal several times with the engine off, ensuring no change in the pedal reserve distance. Start the engine while depressing the pedal; a slight drop indicates normal operation. For an airtightness check, start the engine and turn it off after one or two minutes, then slowly depress the brake pedal several times; if the pedal depresses less each time, the booster is airtight. While the engine runs, depress the brake pedal, then stop the engine with the pedal held down; if there's no change in pedal reserve travel after 30 seconds, the booster is airtight. Power brake booster units should not be disassembled due to their complexity and critical role in brake performance; they should be replaced with new or rebuilt units. To remove the booster, first remove the brake master cylinder, then take out the left side under-dash panel to access the pushrod clevis connecting the booster to the brake pedal. Remove the clevis pin retaining clip and pull out the pin, then unscrew the locknut to loosen the clevis. Disconnect the hose from the engine to the booster, taking care not to damage it, and remove the four nuts and washers securing the brake booster to the firewall. Slide the booster straight out until the studs clear the holes. For installation, follow the reverse of removal, tightening the clevis locknut and booster mounting nuts to the specified torque. If replacing the power booster unit, measure and adjust the clearance between the master cylinder piston and the pushrod in the vacuum booster as necessary, ensuring no clearance or interference exists. Finally, after installing the master cylinder and brake hoses, adjust the brake pedal height and freeplay, and bleed the system.