Disassembly and Assembly

DISASSEMBLY





1. Place hydraulic brake booster in vise.
- Using Special Service Tool (SST) 09630-00014 (09631-00142), 09950-00010 (09951-00180, 09951-00190) or equivalent, set the hydraulic brake booster in vise.

2. Remove reservoir and grommets.
a. Remove reservoir cap.
b. Remove the 3 set screws and pull out the reservoir.
Torque: 1.7 Nm (15.2 inch lbs.)
c. Remove the 3 grommets.

3. Remove clevis and cylinder boot.
a. Loosen the lock nut, then remove the clevis and lock nut.
Torque: 25 Nm (19 ft. lbs.)
b. Remove the cylinder boot.




4. Remove piston.
a. Pressing the piston in with a screwdriver, use a pin or an equivalent to push the snap ring from the hole in the body then remove it with another screwdriver.
b. Remove the piston, pulling straight out, not at an angle.

NOTICE: If pulled out and installed at an angle, there is a possibility that the cylinder bore could be damaged. At the time of reassembly, be careful not to damage the rubber lips on the pistons.




5. Remove brake actuator tube No.1.
- Using SST 09020-00100, remove the brake actuator tube No.1.
Torque: 15 Nm (11 ft. lbs.)

6. Remove booster pump and assembly.
a. Remove the actuator hose.
b. Remove the 4 screws and wire harness from the booster and pump.
c. Remove the 2 bolts, accumulator bracket and brake line clamp.
d. Remove the 2 bolts and booster pump assembly.
e. Remove the bolt and No.1 pump bracket.
f. Remove the 2 washers, 2 cushions, 2 collars and sleeve.
g. Remove the 2 bolts and No.2 pump bracket.
h. Remove the cushion from No.2 pump bracket.




7. Remove accumulator from booster pump.
a. Using SST 09318-12010, remove the accumulator.
Torque: 54 Nm (36 ft. lbs.)
b. Remove the silencer tube, spring and O-ring.

DISPOSAL




1. Disposal method of accumulator.
a. Follow the procedures described below and drain the high pressure fluid from the accumulator.
b. Place the accumulator in a vise, place a cloth over a saw, then cut the accumulator body slowly.

CAUTION: Never cut at a stretch.

c. When the outer body of the accumulator is cut, gas discharges.

REASSEMBLY
Reassembly is in the reverse order of disassembly.




1. Install accumulator bracket.
- When installing the accumulator bracket, adjust to secure the clearance shown in the illustration.

Standard clearance:
A + B: 4.1 mm (0.161 inch) or less
C: 0.3 mm (0.012 - 0.150 inch)

HINT: Secure more than 0.3 mm (0.012 inch) clearance for A and B each.