Toyota Tundra. Manual — part 976

a. Check the check valve.

1. Slide the clip and disconnect the vacuum hose.

2. Remove the check valve from the booster.

3. Check that there is ventilation from the booster to the engine, and no ventilation from the

engine to the booster.

If the results are not as specified, replace the check valve assembly.

Fig. 43: Checking Brake Vacuum Check Valve Assembly
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVAL

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

2. DRAIN BRAKE FLUID

3. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY

a. Remove the brake master cylinder (see REMOVAL ).

4. DISCONNECT VACUUM HOSE ASSEMBLY

a. Slide the clip and disconnect the vacuum hose from the check valve.

5. DISCONNECT BRAKE BOOSTER CONNECTOR

a. Disconnect the 2 brake booster connectors from the brake booster.

NOTE:



Some systems need to be initialized after the cable is reconnected
(see INITIALIZATION ).



After the ignition switch is turned OFF, the navigation system
requires approximately 90 seconds to record various types of
memory and settings. As a result, after turning the ignition switch
OFF, wait 90 seconds or more before disconnecting the cable from
the negative (-) battery terminal.

NOTE:

Immediately wash off any brake fluid that comes into contact with any
painted surfaces.

2009 Toyota Tundra

2009 BRAKES Brake - Tundra

6. REMOVE FRONT DOOR SCUFF PLATE LH (for Regular Cab) (See REMOVAL )

7. REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab) (See REMOVAL )

8. REMOVE COWL SIDE TRIM BOARD LH (See REMOVAL )

9. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH (See

REMOVAL )

10. REMOVE NO. 1 INSTRUMENT PANEL SAFETY PAD INSERT (See REMOVAL )

11. REMOVE PUSH ROD PIN

a. Remove the clip and push rod pin.

12. REMOVE BRAKE BOOSTER ASSEMBLY

a. Remove the 4 nuts, and then pull out the brake booster.

Fig. 44: Identifying Brake Booster Nuts
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

b. Remove the gasket from the brake booster.

c. Loosen the lock nut and then remove the clevis.

13. REMOVE BRAKE VACUUM CHECK VALVE ASSEMBLY

INSTALLATION

1. INSTALL BRAKE VACUUM CHECK VALVE ASSEMBLY

2. INSTALL BRAKE BOOSTER ASSEMBLY

a. Install the clevis.

b. Install a new brake booster gasket to the brake booster.

c. Install the brake booster with the 4 nuts.

Torque: 15 N*m (155 kgf*cm, 11 ft.*lbf)

2009 Toyota Tundra

2009 BRAKES Brake - Tundra

Fig. 45: Identifying Brake Booster Nuts
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

3. INSTALL PUSH ROD PIN (see INSTALLATION )

4. INSTALL NO. 1 INSTRUMENT PANEL SAFETY PAD INSERT (See INSTALLATION )

5. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH (See

INSTALLATION )

6. INSTALL COWL SIDE TRIM BOARD LH (See INSTALLATION )

7. INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab) (See INSTALLATION )

8. INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab) (See INSTALLATION )

9. CONNECT BRAKE BOOSTER CONNECTOR

a. Connect the 2 brake booster connectors to the brake booster.

10. CONNECT VACUUM HOSE ASSEMBLY

a. Connect the vacuum hose onto the check valve.

11. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY

a. Install the brake master cylinder (see INSTALLATION ).

12. CHECK BRAKE PEDAL HEIGHT (see ADJUSTMENT )

13. CHECK BRAKE BOOSTER (see ON-VEHICLE INSPECTION )

14. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

15. FILL RESERVOIR WITH BRAKE FLUID (see REPLACEMENT )

16. BLEED AIR FROM BRAKE MASTER CYLINDER (see REPLACEMENT )

17. BLEED AIR FROM BRAKE LINE (see REPLACEMENT )

18. BLEED AIR FROM VSC ACTUATOR ASSEMBLY (see REPLACEMENT )

19. CHECK BRAKE FLUID LEVEL IN RESERVOIR (see ON-VEHICLE INSPECTION )

NOTE:

Do not use lubricant when installing a vacuum hose on the brake
booster and check valve sides.

NOTE:

Some systems need to be initialized after the cable is reconnected (see
INITIALIZATION ).

2009 Toyota Tundra

2009 BRAKES Brake - Tundra

20. CHECK FOR BRAKE FLUID LEAK

FRONT BRAKE

COMPONENTS

Fig. 46: Identifying Front Brake Components And Torque Specifications
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVAL

HINT:

2009 Toyota Tundra

2009 BRAKES Brake - Tundra