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Home >> Toyota >> 2021 >> Highlander LE, 4WD >> Repair and Diagnosis >> Brakes >> Anti-Lock Brakes >> Brake Control System - Service Information >> BRAKE ACTUATOR (for Gasoline Model) >> Removal [12/2019 - 10/2022] >> Procedure

Removal [12/2019 - 10/2022]: Procedure

  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 

    Refer to PROCEDURE - Step 1

    NOTE:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

    Refer to INITIALIZATION [12/2019 - 09/2020] , or refer to INITIALIZATION [09/2020 - 10/2021] , or refer to INITIALIZATION [10/2021 - 10/2022]

  2. DRAIN BRAKE FLUID 
    NOTE:

    If brake fluid leaks onto any painted surface, immediately wash it off.

  3. REMOVE FRONT WHEEL RH 

    Refer to REMOVAL [12/2019 - 10/2022]

  4. REMOVE FRONT FENDER APRON SEAL RH 

    Refer to PROCEDURE - Step 16 [12/2019 - 09/2020] , or refer to PROCEDURE - Step 16 [09/2020 - 10/2022]

  5. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    Refer to REMOVAL [12/2019 - ]

  6. REMOVE FENDER SPLASH SHIELD SUB-ASSEMBLY REAR LH 

    Refer to PROCEDURE - Step 3

  7. REMOVE FENDER SPLASH SHIELD SUB-ASSEMBLY REAR RH 

    HINT: 

    Perform the same procedure as for the LH side.

  8. REMOVE FRONT FENDER SPLASH SHIELD SEAL FRONT LH 

    Refer to PROCEDURE - Step 5

  9. REMOVE FRONT FENDER SPLASH SHIELD SEAL FRONT RH 

    HINT: 

    Perform the same procedure as for the LH side.

  10. REMOVE FRONT UPPER SUSPENSION TO COWL BRACE SUB-ASSEMBLY LH 

    Refer to PROCEDURE - Step 7

  11. REMOVE FRONT UPPER SUSPENSION TO COWL BRACE SUB-ASSEMBLY RH 

    HINT: 

    Perform the same procedure as for the LH side.

  12. REMOVE COWL VENTILATOR PANEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 9

  13. SEPARATE HEATER WATER PUMP ASSEMBLY (w/ Stop and Start System) 
    1. Remove the bolt and 3 nuts to separate the heater water pump assembly.
      GTY912136Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE BRAKE ACTUATOR WITH BRACKET 
    1. Release the lock lever and disconnect the connector from the brake actuator assembly.
      GTY864942Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Release the lock lever
      Disconnect the connector
      NOTE:

      Be careful not to allow any brake fluid to enter the connector.

    2. Remove the 2 bolts to separate the brake lines.
      GTY912133Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Use tags or make a memo to identify the places to reconnect the brake lines.
      GTY876302Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a From 1st Chamber of Brake Master Cylinder Sub-assembly
      *b From 2nd Chamber of Brake Master Cylinder Sub-assembly
      *c To Front Wheel Cylinder Assembly RH
      *d To Rear Wheel Cylinder Assembly LH
      *e To Rear Wheel Cylinder Assembly RH
      *f To Front Wheel Cylinder Assembly LH
    4. Using a union nut wrench, disconnect the 6 brake lines from the brake actuator assembly.
      GTY912134Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • 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.
    5. Using a union nut wrench, disconnect the front brake tube while holding the front flexible hose with a wrench.
      GTY912130Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not kink or damage the front brake tube.
      • Do not allow any foreign matter such as dirt or dust to enter the front brake tube from the connecting parts.
    6. Disengage the clamp and separate the front brake tube.
      GTY912131Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not kink or damage the front brake tube.

    7. Move aside the front brake tube as shown in the illustration.
      GTY942485Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not apply excessive force to the front brake tube.

    8. Disengage the clamp and remove the brake tube clamp.
      GTY912112Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Apply protective tape to the vehicle body as shown in the illustration.
      GTY917844Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
    10. Remove the 2 bolts.
      GTY912111Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Insert the tool from the bottom of the vehicle.

    11. Remove the nut and brake actuator with bracket.
      NOTE:
      • 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.
      • Be careful not to allow any brake fluid to enter the connector.
      • Do not hold the brake actuator with bracket by the connector.
      • Do not drop the brake actuator with bracket when carrying it.

      HINT: 

      Remove the brake actuator with bracket while avoiding the brake lines.

  15. REMOVE BRAKE ACTUATOR ASSEMBLY 
    1. Remove the 3 bolts and brake actuator assembly from the brake actuator bracket assembly.
      GTY912108Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not hold the brake actuator assembly by the connector.
      • Do not drop the brake actuator assembly when carrying it.
  16. REMOVE NO. 2 BRAKE ACTUATOR CASE COLLAR 

    HINT: 

    Perform this procedure only when replacement of the No. 2 brake actuator case collars is necessary.

    1. Remove the 3 nuts.
      GTY912109Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 No. 2 brake actuator case collars from the brake actuator bracket cushion.
  17. REMOVE BRAKE ACTUATOR BRACKET CUSHION 

    HINT: 

    Perform this procedure only when replacement of the brake actuator bracket cushions is necessary.

    1. Remove the 3 brake actuator bracket cushions from the brake actuator bracket assembly.
      GTY942484Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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