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Hydraulic Brake Booster Dissasembly LC200

The document provides step-by-step instructions to disassemble a hydraulic brake booster. It involves removing 11 different components, including the brake actuator bracket, master cylinder reservoir, hoses and tubes, brake booster assembly, solenoid, push rod clevis, boot, and piston sub-assembly. Special tools like wrenches and punches are required to remove pins, bolts, and nuts. Cautions are provided to avoid damaging parts during removal.

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Yannick de Walque
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990 views10 pages

Hydraulic Brake Booster Dissasembly LC200

The document provides step-by-step instructions to disassemble a hydraulic brake booster. It involves removing 11 different components, including the brake actuator bracket, master cylinder reservoir, hoses and tubes, brake booster assembly, solenoid, push rod clevis, boot, and piston sub-assembly. Special tools like wrenches and punches are required to remove pins, bolts, and nuts. Cautions are provided to avoid damaging parts during removal.

Uploaded by

Yannick de Walque
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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HYDRAULIC BRAKE BOOSTER (for

LHD) > DISASSEMBLY


for Preparation Click here

1. REMOVE NO. 1 BRAKE ACTUATOR BRACKET

1. Using a 5 mm hexagon wrench, remove the bolt and No. 1 brake actuator bracket.

2. Using a screwdriver, disconnect the brake fluid level warning switch connector from
the No. 1 brake actuator bracket.
2. REMOVE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY

1. Using a pin punch and hammer, remove the pin from the brake master cylinder
reservoir.

2. Remove the screw and pull out the brake master cylinder reservoir sub-assembly.

3. Remove the master cylinder reservoir filler cap.

3. REMOVE MASTER CYLINDER RESERVOIR GROMMET


1. Remove the 3 reservoir grommets from the master cylinder reservoir.

4. REMOVE NO. 1 BRAKE ACTUATOR HOSE

1. Using needle nose pliers, slide the 2 clips and remove the brake actuator hose and 2
clips.

5. REMOVE NO. 1 BRAKE ACTUATOR TUBE


1. Using a union nut wrench, remove the No. 1 brake actuator tube.

6. REMOVE BRAKE BOOSTER WITH ACCUMULATOR PUMP ASSEMBLY

1. Using a screwdriver, remove the 2 plugs.


2. Remove the 2 screws and disconnect the wire harnesses from the master cylinder
solenoid.

3. Using a screwdriver, remove the clip.


4. Remove the brake booster with accumulator pump assembly from the brake master
cylinder.

5. Remove the 2 brake booster pump collars and 2 brake booster pump bushes from the
brake booster with accumulator pump assembly.

6. Using a 4 mm hexagon wrench, remove the 2 pins.

7. REMOVE NO. 1 BRAKE BOOSTER PUMP BRACKET

1. Using a 5 mm hexagon wrench, remove the 2 bolts and No. 1 brake booster pump
bracket from the brake master cylinder solenoid.

2. Remove the brake booster pump bush from the No. 1 brake booster pump bracket.
8. REMOVE BRAKE BOOSTER ACCUMULATOR PIPE

1. Secure the brake booster with accumulator pump assembly in a vise.

2. Remove the brake booster accumulator.

3. Remove the O-ring from the brake booster accumulator.

NOTICE:
Ensure no foreign matter enters the pump.

4. Remove the brake booster accumulator pipe and compression spring.

9. REMOVE MASTER CYLINDER SOLENOID


1. Remove the 6 bolts and master cylinder solenoid.

2. Remove the gasket.

10. REMOVE MASTER CYLINDER PUSH ROD CLEVIS

1. Loosen the lock nut on the rod operating adapter, and remove the push rod clevis and
lock nut.
2. Loosen the lock nut on the brake master cylinder side, and remove the rod operating
adapter and lock nut.

11. REMOVE MASTER CYLINDER BOOT

12. REMOVE BRAKE BOOSTER PISTON SUB-ASSEMBLY

1. Pressing the piston in with a screwdriver, insert a pin or equivalent from the hole in
the master cylinder body to hold the C-ring, and then remove it with another
screwdriver.

HINT:
Tape the screwdriver tip before use.

2. Remove the plug from the piston.

3. Remove the piston by pulling it straight out, not at an angle.


NOTICE:
If the piston is pulled out at an angle, there is a possibility that the cylinder bore could
be damaged.

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