BRAKE SYSTEM (OTHER): BRAKE BOOSTER (w/ Vacuum Brake Booster): REMOVAL; 2024 MY RAV4 RAV4 HV [10/2023

Last Modified: 01-30-2024	6.11:8.1.0	Doc ID: RM100000002FR6B
Model Year Start: 2024	Model: RAV4	Prod Date Range: [10/2023 - ]
Title: BRAKE SYSTEM (OTHER): BRAKE BOOSTER (w/ Vacuum Brake Booster): REMOVAL; 2024 MY RAV4 RAV4 HV [10/2023 - ]

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during brake booster assembly removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure	Necessary Procedure	Effect/Inoperative Function when Necessary Procedure not Performed
1: When performing learning using the Techstream. Click here 2: w/o Power Back Door System
Battery terminal is disconnected/reconnected	Drive the vehicle until stop and start control is permitted (approximately 5 to 60 minutes)	Stop and start system
	Perform steering sensor zero point calibration	Lane control system
		Parking support brake system (for Gasoline model)*1
		Pre-collision system
	Reset back door close position	Power back door system
	Back door lock initialization*2	Power door lock control system

NOTICE:

After the ignition switch is turned off, the audio and visual system records various types of memory and settings. As a result, after turning the ignition switch off, make sure to wait at least 2 minutes before disconnecting the cable from the negative (-) auxiliary battery terminal.
When the cable is disconnected from the negative (-) auxiliary battery terminal and the security lock setting has been enabled, multi-display operations will be disabled upon next startup unless the password is entered. Be sure to check the security lock setting before disconnecting the cable from the negative (-) auxiliary battery terminal.
Make sure to release vacuum from the brake booster assembly before removing the brake master cylinder sub-assembly from the brake booster assembly.

PROCEDURE

1. PRECAUTION

CAUTION:

Be sure to read precaution thoroughly before servicing.

Click here

NOTICE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

Click here

2. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY

Click here

3. REMOVE ECM

Click here

4. REMOVE BATTERY CLAMP SUB-ASSEMBLY

Click here

5. REMOVE LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY

Click here

6. REMOVE NO. 1 AIR DUCT (for TMC Made)

Click here

7. REMOVE NO. 2 AIR DUCT SUB-ASSEMBLY (for TMMC Made)

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8. REMOVE STOP LIGHT SWITCH ASSEMBLY

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9. REMOVE BRAKE PEDAL RETURN SPRING

Click here

10. SEPARATE WIRE HARNESS

(a) Disconnect the connector.

(b) Disengage the 2 clamps to separate the wire harness from the brake pedal support assembly.

11. LOOSEN LOCK NUT

(a) Loosen the lock nut of the brake master cylinder push rod clevis.

*1	Lock Nut
*2	Brake Master Cylinder Push Rod Clevis

12. REMOVE PUSH ROD PIN

Click here

13. DISCONNECT CHECK VALVE TO CONNECTOR TUBE HOSE

(a) Slide the clip and disconnect the check valve to connector tube hose from the brake booster assembly.

14. REMOVE BRAKE BOOSTER ASSEMBLY

(a) Remove the bolt and nut.

(b) Disengage the guide and separate the wire harness.

Protective Tape

(d) Disconnect the connector from the vacuum warning switch assembly.

(e) w/ Stop and Start System:

(1) Disconnect the connector from the vacuum sensor assembly.

(f) Disengage the 5 clamps to separate the brake tube clamp from the brake lines.

(g) Disengage the 5 clamps to remove the brake tube clamp from the brake lines.

(h) Disengage the 5 clamps to remove the brake tube clamp from the brake lines.

(i) Disengage the 3 clamps to separate the brake tube clamp from the brake lines.

(j) Remove the bolt and clamp to remove the 2 brake tube clamps from the vehicle body.

(k) Using a union nut wrench, remove the 2 brake lines from the brake actuator assembly.

NOTICE:

Do not kink or damage the brake lines.
Do not allow any foreign matter such as dirt or dust to enter the brake lines from the connecting parts.

*a	From 1st Chamber of Brake Master Cylinder Sub-assembly
*b	From 2nd Chamber of Brake Master Cylinder Sub-assembly

(l) Remove the 4 nuts.

NOTICE:

Do not apply excessive force to the brake lines.

(m) Remove the brake master cylinder push rod clevis and lock nut from the brake booster assembly.

(n) Remove the brake booster assembly from the vehicle body.

NOTICE:

Do not apply excessive force to the brake lines.

15. REMOVE BRAKE BOOSTER GASKET

(a) Remove the brake booster gasket from the brake booster assembly.