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Brake: Removal & Installation Scion xB I

Mechanical - Hydraulic 38 illustrations ~2094 words

REPLACEMENT

HINT

See COMPONENT

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Scheme 2: REPLACEMENT
Scheme 2: REPLACEMENT

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Scheme 11
  1. DRAIN BRAKE FLUID NOTE: Wash the brake fluid off immediately if it adheres to any painted surfaces.
  2. REMOVE AIR CLEANER CAP SUB-ASSY
  3. DISCONNECT CLUTCH RESERVOIR TUBE (M/T TRANSAXLE) Slide the clip and disconnect the clutch reservoir tube.
  4. REMOVE BRAKE MASTER CYLINDER Disconnect the level warning light switch connector. Using SST, disconnect the 2 brake lines from the brake master cylinder. SST 09023-00101 Remove the 2 nuts, and pull out the brake master cylinder.
  5. REMOVE BRAKE MASTER LESS RESERVOIR TANK CYLINDER SUB-ASSY Pull out the brake master cylinder reservoir tank stopper. Remove the brake master cylinder reservoir and 2 grommets. Remove the cap and strainer from the brake master cylinder reservoir.
  6. INSTALL BRAKE MASTER LESS RESERVOIR TANK CYLINDER SUB-ASSY Apply lithium soap base glycol grease to the 2 grommets and install them onto the brake master less reservoir tank cylinder. Install the cap and strainer to the brake master cylinder reservoir. Install the brake master cylinder reservoir assy with the brake master cylinder reservoir tank stopper. NOTE: Install the stopper securely to the groove of the reservoir and master cylinder.
  7. INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD NOTE: Make an adjustment with the brake booster assy having no vacuum. (Depress the brake pedal several times with the engine stopped.) HINT: Adjustment of the brake booster push rod is performed when the brake master cylinder sub-assy is replaced with a new one. The adjustment is not necessary when the brake master cylinder sub-assy is reinstalled and the brake booster assy is replaced with a new one. Apply the chalk to the tip of an accessory tool. HINT: The accessory tool is enclosed with new brake master cylinder sub-assy. Place the accessory tool in the brake booster assy. Measure the clearance between the brake booster push rod and accessory tool. Clearance: 0 mm (0 in.) HINT: Adjust the clearance in the following cases: If there is a clearance between the accessory tool and the shell of the brake booster (floating accessory tool), the clearance is too small. If the chalk does not stick on the tip of the brake booster push rod, the clearance is large. If clearance is outside of the specified range, fix the push rod using SST and adjust the length of the protruding adjusting bolt. SST 09737-00020 HINT: When adjusting the push rod, depress the brake pedal sufficiently so that the push rod sticks out.
  8. INSTALL BRAKE MASTER CYLINDER Install the brake master cylinder to the booster with the 2 nuts. Torque: 13 N.m (127 kgf.cm, 9 ft.lbf) Using SST, connect the 2 brake lines to the brake master cylinder. SST 09023-00101 Torque: 15 N.m (155 kgf.cm, 11 ft.lbf) Connect the level warning light switch connector.
  9. CONNECT CLUTCH RESERVOIR TUBE (M/T TRANSAXLE) Slide the clip and connect the clutch reservoir tube.
  10. INSTALL AIR CLEANER CAP SUB-ASSY
  11. FILL RESERVOIR WITH BRAKE FLUID (See «BRAKE FLUID (FROM APRIL, 2004)»(ref-224552-S32316981482006031000000) )
  12. BLEED MASTER CYLINDER (See «BRAKE FLUID (FROM APRIL, 2004)»(ref-224552-S32316981482006031000000) )
  13. BLEED CLUTCH LINE (M/T TRANSAXLE) (See «OVERHAUL»(ref-224556-S37739300102006031000000) )
  14. CHECK FLUID LEVEL IN RESERVOIR (See «BRAKE FLUID (FROM APRIL, 2004)»(ref-224552-S32316981482006031000000) )
  15. CHECK FOR BRAKE FLUID LEAKAGE

Scheme 12

Scheme 12: ON-VEHICLE INSPECTION
Scheme 12: ON-VEHICLE INSPECTION

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Scheme 13

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Scheme 14
  1. INSPECT BRAKE BOOSTER Airtightness check. Start the engine and stop it after 1 or 2 minutes. Depress the brake pedal several times slowly. HINT: If the pedal goes down farthest at the 1st time, but gradually rises at the 2nd or 3rd time, the booster is airtight. Depress the brake pedal while the engine is running, and stop the engine with the pedal depressed. HINT: If there is no change in the pedal reserve distance after holding the pedal for 30 seconds, the booster is airtight. Operating check. Depress the brake pedal several times with the ignition switch off and check that there is no change in the pedal reserve distance. Depress the brake pedal and start the engine. HINT: If the pedal goes down slightly, the operation is normal.
  2. INSPECT VACUUM CHECK VALVE Inspect the vacuum check valve. Slide the clip and disconnect the vacuum hose. Remove the vacuum check valve. Check that there is ventilation from the booster to the engine, and no ventilation from the engine to the booster. If any fault is found, replace the vacuum check valve.

Scheme 15

Scheme 15: COMPONENT
Scheme 15: COMPONENT

Note. Wash the brake fluid off immediately if it adheres to any painted surfaces.

Scheme 16

Scheme 16: REPLACEMENT
Scheme 16: REPLACEMENT

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Scheme 23
  1. DRAIN BRAKE FLUID
  2. REMOVE AIR CLEANER CAP SUB-ASSY
  3. DISCONNECT CLUTCH RESERVOIR TUBE (M/T TRANSAXLE) Slide the clip and disconnect the clutch reservoir tube.
  4. REMOVE BRAKE MASTER CYLINDER (See «REPLACEMENT»(ref-224552-S09277191372006031000000) ) SST 09023-00101
  5. REMOVE BATTERY
  6. REMOVE BRAKE ACTUATOR WITH BRACKET (See «REPLACEMENT»(ref-224552-S33194414312006031000000) )
  7. REMOVE BRAKE BOOSTER ASSY Slide the clip and disconnect the vacuum hose from the brake booster assy. Remove the brake pedal return spring, the clip and the clevis pin. Loosen the push rod clevis lock nut. Remove the 4 nuts and push rod clevis. Pull out the brake booster assy and the gasket.
  8. INSTALL BRAKE BOOSTER ASSY Install the brake booster assy and a new gasket. Install the brake booster assy with the 4 nuts and push rod clevis. Torque: 13 N.m (130 kgf.cm, 9 ft.lbf) Apply lithium soap base glycol grease to the clevis pin. Install the clip and the clevis pin. NOTE: The direction for the clip installation is as follows. Install the brake pedal return spring. Connect the vacuum hose to the brake booster assy and slide the clip.
  9. INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD NOTE: Make an adjustment with the brake booster assy having no vacuum. (Depress the brake pedal several times with the engine stopped.) HINT: Adjustment of the brake booster push rod is performed when the brake master cylinder sub-assy is replaced with a new one. The adjustment is not necessary when the brake master cylinder sub-assy is reinstalled and the brake booster assy is replaced with a new one. Apply the chalk to the tip of an accessory tool. HINT: Then accessory tool is enclosed with a new brake master cylinder sub-assy. Place the accessory tool in the brake booster assy. Measure the clearance between the brake booster push rod and accessory tool. Clearance: 0 mm (0 in.) HINT: Adjust the clearance in the following cases: If there is a clearance between the accessory tool and the shell of the brake booster (floating accessory tool), the clearance is too small. If the chalk does not stick on the tip of the brake booster push rod, the clearance is large. If clearance is outside of the specified range, fix the push rod using SST and adjust the length of the protruding adjusting bolt. SST 09737-00020 HINT: When adjusting the push rod, depress the brake pedal sufficiently so that the push rod sticks out.
  10. INSTALL BRAKE ACTUATOR WITH BRACKET (See «REPLACEMENT»(ref-224552-S33194414312006031000000) )
  11. INSTALL BRAKE MASTER CYLINDER (See «REPLACEMENT»(ref-224552-S09277191372006031000000) ) SST 09023-00101
  12. INSTALL CLUTCH RESERVOIR TUBE (M/T TRANSAXLE) Slide the clip and connect the clutch reservoir tube.
  13. INSTALL AIR CLEANER CAP SUB-ASSY
  14. INSTALL BATTERY
  15. FILL RESERVOIR WITH BRAKE FLUID (See «BRAKE FLUID (FROM APRIL, 2004)»(ref-224552-S32316981482006031000000) )
  16. BLEED MASTER CYLINDER (See «BRAKE MASTER CYLINDER SUB-ASSY (FROM APRIL, 2004)»(ref-224552-S16461096812006031000000) )
  17. BLEED BRAKE LINE (See «BRAKE FLUID (FROM APRIL, 2004)»(ref-224552-S32316981482006031000000) )
  18. BLEED CLUTCH LINE (M/T TRANSAXLE) (See «OVERHAUL»(ref-224556-S37739300102006031000000) )
  19. CHECK AND ADJUST BRAKE PEDAL HEIGHT (See «ADJUSTMENT»(ref-224552-S17543161112006031000000) )
  20. CHECK PEDAL FREE PLAY (See «BRAKE PEDAL SUB-ASSY»(ref-224552-S22687811992006031000000) )
  21. CHECK PEDAL RESERVE DISTANCE (See «BRAKE PEDAL SUB-ASSY»(ref-224552-S22687811992006031000000) )
  22. CHECK FLUID LEVEL IN RESERVOIR (See «BRAKE FLUID (FROM APRIL, 2004)»(ref-224552-S32316981482006031000000) )
  23. CHECK FOR BRAKE FLUID LEAKAGE
  24. CHECK BRAKE ACTUATOR WITH HAND-HELD TESTER (See «DIAGNOSIS SYSTEM»(ref-224519-S41959349852006031000000) )

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Scheme 24: COMPONENTS
Scheme 24: COMPONENTS

HINT

Replace the RH side by using the same procedures as those for the LH side.

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Scheme 25: REPLACEMENT
Scheme 25: REPLACEMENT

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  1. REMOVE FRONT WHEEL
  2. REMOVE BATTERY
  3. REMOVE SPEED SENSOR FRONT LH Disconnect the speed sensor connector. Remove the 2 clamp bolts holding the speed sensor wire harness from the body and the shock absorber. Disconnect the resin clip and the speed sensor wire harness from the shock absorber. Remove the bolt and the speed sensor front LH. NOTE: Prevent foreign matter from attaching to the sensor tip.
  4. INSTALL SPEED SENSOR FRONT LH Install the speed sensor front LH with the bolt. Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf) NOTE: Prevent foreign matter from attaching to the sensor tip. Install the speed sensor wire harness with the 2 bolts on the body and the shock absorber. Torque: Bolt A: 8.0 N.m (82 kgf.cm, 71 in.lbf) Bolt B: 29 N.m (300 kgf.cm, 22 ft.lbf) NOTE: Do not twist the sensor wire when installing the sensor. Connect the resin clip and the speed sensor wire harness to the shock absorber. Connect the speed sensor connector.
  5. INSTALL FRONT WHEEL Torque: 103 N.m (1,050 kgf.cm, 76 ft.lbf)
  6. INSTALL BATTERY
  7. CHECK ABS SPEED SENSOR SIGNAL (See «DIAGNOSIS SYSTEM»(ref-224519-S41959349852006031000000) )

HINT

Replace the RH side by using the same procedures as those for the LH side.

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Scheme 31: REPLACEMENT
Scheme 31: REPLACEMENT

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Scheme 35
  1. REMOVE REAR WHEEL
  2. DISCONNECT SKID CONTROL SENSOR WIRE Disconnect the connector from the skid control sensor.
  3. REMOVE REAR BRAKE DRUM SUB-ASSY Put matchmarks on the rear brake drum sub-assy and the axle hub. Remove the rear brake drum sub-assy.
  4. REMOVE REAR AXLE HUB & BEARING ASSY LH (See «REPLACEMENT»(ref-224551-S21725962512006031100000) )
  5. REMOVE SKID CONTROL SENSOR Mount the hub & bearing assy in a soft jaw vise. NOTE: Replace the hub & bearing assy if it is dropped or receives a strong shock. Using a pin punch and hammer, drive out the 2 pins, and remove the 2 attachments from SST. Using SST and 2 bolts (Diameter: 12 mm, pitch: 1.5 mm), remove the skid control sensor from the rear axle hub. SST 09520-00031 (09520-00040), 09521-00020, 09950-00020 NOTE: If the sensor rotor is damaged, replace the hub & bearing assy. Do not scratch the contacting surface of the hub & bearing assy and the skid control sensor.
  6. INSTALL SKID CONTROL SENSOR Clean the contacting surface of the rear axle hub and a new skid control sensor. NOTE: Make sure the sensor rotor is clean. Place the skid control sensor in the rear axle hub so that the connector makes the lowest position under the on vehicle condition. Using SST and a press, install the skid control sensor onto the hub & bearing assy. SST 09214-76011 NOTE: Do not tap the skid control sensor directly with a hammer. Check that the skid control sensor detection part is clean. Press in the skid control sensor straight and slowly.
  7. INSTALL REAR AXLE HUB & BEARING ASSY LH (See «REPLACEMENT»(ref-224551-S21725962512006031100000) )
  8. INSPECT REAR AXLE DEVIATION AND BACKLASH (See «ON-VEHICLE INSPECTION»(ref-224551-S20918650232006031100000) )
  9. INSTALL REAR BRAKE DRUM SUB-ASSY Aligning the matchmarks, install the rear brake drum sub-assy.
  10. CONNECT SKID CONTROL SENSOR WIRE Connect the connector to the skid control sensor.
  11. INSTALL REAR WHEEL Torque: 103 N.m (1,050 kgf.cm, 76 ft.lbf)
  12. CHECK ABS SPEED SENSOR SIGNAL (See «DIAGNOSIS SYSTEM»(ref-224519-S41959349852006031000000) )

Note. Don't use the dropped or damaged yawrate sensor. Free from the foreign matters between yawrate sensor bracket and body. Make sure the sensor direction.

Scheme 36

Scheme 36: REPLACEMENT
Scheme 36: REPLACEMENT

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Scheme 37
Scheme 37
  1. REMOVE CONSOLE BOX SUB-ASSY REAR
  2. REMOVE YAWRATE SENSOR Disconnect the yawrate sensor connector. Remove the 2 bolts and yawrate sensor.
  3. INSTALL YAWRATE SENSOR Connect the yawrate sensor connector. Install the yawrate sensor with the 2 bolts. Torque: 14 N.m (143 kgf.cm, 10 ft.lbf)
  4. INSTALL CONSOLE BOX SUB-ASSY REAR
  5. PERFORM YAWRATE SENSOR ZERO POINT CALIBRATION (See «CALIBRATION»(ref-224519-S15828346482006031000000) )
  6. CHECK VSC SENSOR SIGNAL (See «DIAGNOSIS SYSTEM»(ref-224519-S41959349852006031000000) )

Scheme 38

Scheme 38: REPLACEMENT
Scheme 38: REPLACEMENT

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Scheme 39
  1. PRECAUTION (See «PRECAUTION»(ref-224560-S32082551342006031000000) )
  2. SEPARATE BATTERY NEGATIVE TERMINAL
  3. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
  4. REMOVE HORN BUTTON ASSY (SEE «OVERHAUL»(ref-224557-S04627223272006031000000) )
  5. REMOVE STEERING WHEEL ASSY (SEE «OVERHAUL»(ref-224557-S04627223272006031000000) )
  6. REMOVE STEERING COLUMN COVER (SEE «OVERHAUL»(ref-224557-S04627223272006031000000) )
  7. REMOVE SPIRAL CABLE SUB-ASSY (See «REPLACEMENT»(ref-224560-S06417413462006031000000) )
  8. REMOVE STEERING SENSOR Release 4 claw fittings and remove the steering sensor from the spiral cable.
  9. INSTALL STEERING SENSOR Install the steering sensor to the spiral cable. NOTE: Install the claw securely. Do not damage the claw.
  10. ADJUST CENTER FRONT WHEEL
  11. INSTALL SPIRAL CABLE SUB-ASSY (See «REPLACEMENT»(ref-224560-S06417413462006031000000) )
  12. CENTER SPIRAL CABLE (See «REPLACEMENT»(ref-224560-S06417413462006031000000) )
  13. INSTALL STEERING WHEEL ASSY (SEE «OVERHAUL»(ref-224557-S04627223272006031000000) )
  14. INSPECT STEERING WHEEL CENTER POINT
  15. INSTALL HORN BUTTON ASSY (See «REPLACEMENT»(ref-224560-S39411188922006031000000) )
  16. INSPECT HORN BUTTON ASSY (See «REPLACEMENT»(ref-224560-S39411188922006031000000) )
  17. INSPECT SRS WARNING LIGHT (See «DIAGNOSIS SYSTEM»(ref-224525-S28807549002006031100000) )
  18. PERFORM VSC SYSTEM CALIBRATION (See «CALIBRATION»(ref-224519-S15828346482006031000000) )
  19. ABS WARNING LIGHT AND VSC WARNING LIGHT (See «DIAGNOSIS SYSTEM»(ref-224519-S41959349852006031000000) )

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