1. Gather necessary tools and materials:
- Replacement master cylinder
- Brake fluid (DOT3)
- Brake line wrench
- Socket wrench set
- Open-end wrench
- Pliers
- Rags
- Funnel
- Small container for brake fluid
2. Preparations:
-Park the vehicle on level ground and apply the parking brake.
-Turn off the engine and allow it to cool down completely.
-Locate the brake fluid reservoir and remove its cover.
3. Disconnect brake lines:
-Use a brake line wrench to disconnect the brake lines from the master cylinder. Be sure to keep a container nearby to collect any brake fluid that leaks.
-Plug the brake lines to prevent fluid loss.
4. Remove the old master cylinder:
-Use a socket wrench to loosen and remove the nuts holding the master cylinder to the brake booster.
-Carefully remove the old master cylinder from the vehicle.
5. Prepare the new master cylinder:
-Before installing the new master cylinder, make sure to remove any protective caps or plugs.
-Check that the pushrod is in place and moves smoothly.
6. Install the new master cylinder:
-Position the new master cylinder in place, ensuring it sits correctly against the brake booster.
-Secure the master cylinder using the nuts removed earlier.
7. Reconnect the brake lines:
-Reconnect the brake lines to the master cylinder, hand-tightening them initially.
-Use the brake line wrench to tighten the brake lines securely, but avoid over-tightening.
8. Fill with brake fluid:
-Use a funnel to fill the brake fluid reservoir to the appropriate level indicated in the owner's manual.
-Bleed the brake lines to remove any trapped air in the system. This involves opening and closing the brake bleeder screws at each wheel while depressing the brake pedal until all air is removed and only clean brake fluid comes out.
-Repeat the bleeding process for all four wheels, following the proper bleeding sequence as specified in the service manual.
9. Test the brakes:
-Start the engine and press the brake pedal firmly several times to build up pressure in the system.
-Test the brakes by applying pressure to the pedal. Verify that the brakes engage smoothly and the vehicle stops effectively.
10. Check brake fluid level:
-After the bleeding process and testing the brakes, recheck the brake fluid level in the reservoir and top up if necessary.
11. Clean up:
-Clean any spilled brake fluid thoroughly with a rag or brake cleaner.
-Replace the reservoir cover and return any tools and materials used.
Remember that brake work can be critical to vehicle safety, so proper procedures should be followed, and in case of uncertainty or lack of experience, it's advisable to consult a qualified mechanic or refer to the Toyota service manual for specific details related to your van.
