Last Modified: 4-30-2014 6.6 A Doc ID: RM0000019ZF001X
Model Year: 2006 Model: LX470 Prod Date Range: [05/2005 -           ]
Title: BRAKE: HYDRAULIC BRAKE BOOSTER: REASSEMBLY; 2006 MY LX470 [05/2005 -        ]

REASSEMBLY

1. INSTALL BRAKE BOOSTER ACCUMULATOR ASSEMBLY

(a) Install the silencer, spring and a new O-ring.

(b) Using SST, install the accumulator.

SST: 09318-12010

Torque:

54 N·m {550 kgf·cm, 36ft·lbf}

2. INSTALL PISTON

NOTICE:

  • If the piston is installed at an angle, there is possibility that the cylinder bore could be damaged.
  • Be careful not to damage the rubber lips on the pistons.

3. INSTALL OIL PRESSURE SENSOR

(a) Using a 30 mm deep socket, install the oil pressure sensor.

Torque:

81 N·m {830 kgf·cm, 60ft·lbf}

NOTICE:

If replacing the pressure sensor, since the sensor is non-reusable, use a sensor of the supply part No. shown below.

Part No.:

89637-30050

4. INSTALL BRAKE BOOSTER PUMP ASSEMBLY

(a) Install the cushion to the No. 2 pump bracket.

(b) Install the No. 2 pump bracket with the 2 bolts.

(c) Install the 2 washers, 2 cushions, 2 collars and sleeve.

(d) Install the No. 1 pump bracket with the bolt.

(e) Install the booster pump with the 2 bolts.

(f) Install the accumulator bracket with the 2 bolts.

(1) When installing the accumulator bracket, adjust to secure the clearance as shown in the illustration.

A + B:

0.1 mm (0.161 in.) or less

C:

0.3 to 3.8 mm (0.012 to 0.150 in.)

HINT:

Secure more than 0.3 mm (0.012 in.) clearance for A and B each.

(g) Install the wire harness to the booster pump with the 4 screws.

(h) Install the actuator hose.

5. INSTALL NO. 1 BRAKE ACTUATOR TUBE

(a) Using SST, install the actuator tube.

SST: 09023-00101

Torque:

15 N·m {155 kgf·cm, 11ft·lbf} without SST

14 N·m {143 kgf·cm, 10ft·lbf} with SST

HINT:

Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

6. INSTALL CYLINDER BOOT

(a) Install the cylinder boot.

7. INSTALL MASTER CYLINDER PUSH ROD CLEVIS

(a) Install the clevis and lock nut.

(b) Tighten the lock nut.

Torque:

25 N·m {260 kgf·cm, 19ft·lbf}

8. INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY

(a) Install the 3 grommets.

(b) Install the reservoir with the 3 screws.

Torque:

1.7 N·m {17.5 kgf·cm, 15.2in·lbf}

(c) Install the reservoir cap.

9. INSTALL FLUID LEVEL WARNING SWITCH CONNECTOR CLAMP

(a) Install the clamp with the bolt.

(b) Connect the connector.