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DIY: Remove stock abs/vsc master cylinder ---> Install power brake booster & master

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Old 03-05-12, 06:00 PM   #1
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Default DIY: Remove stock abs/vsc master cylinder ---> Install power brake booster & master

My disclaimer: this may not be 100% complete as some fabbing/creativity is involved. Do this at your own risk. I am not liable for any reason if you attempt this.


This is what i did to remove the entire ABS/VSC/TRAC system out of my 03 GS300.

parts i used:
Wilwood prop valve
3/16 compression tee's
new gaskets
new nuts with built in lock washers

the booster and master cylinder are from a 2000 Toyota Avalon. The booster bolt pattern is identical to the GS, so no drilling/modifying/hacking up the firewall. Help from a friend at Toyota for that tip!

1. remove all fuses, relays, buzzer, abs/vsc ecu
- remove 3 relays next to the unit
- remove abs ecu under dash
- remove buzzer next to ecu under dash
- remove 100a fuse next to battery (yellow circle)
- remove 40a fuse next to battery (grey circle)

2. remove stock unit
-unplug all harnesses to the unit
- remove bolt betwen pedal and booster
- remove 4 bolts under dash at pedal assembly
- remove 2 front lines from unit
- remove 2 rear lines from unit
carefully remove the whiole unit

3. install new booster/master
- install booster alone with gasket and nuts.
- install master cyl with gasket and tighten
- measure distance and make a spaces to thread on booster to attach to pedal

4. new lines
- cut, then crimp the lines inverted double flare the old lines to size and length
OR get stainless lines made
- put the 2 rears into a Tee and then to willwood prop valve OUT
- put the wilwood IN to the master furthest away from the firewall
- put the front lines into a Tee and then to the master closest to firewall
- bleed the lines and follow wilwoods instructions to set and test and dial in the prop valve. BE CAREFUL AND UNDERSTAND HOW IT WORKS BEFORE YOU GO ADJUSTING IT.
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Old 03-05-12, 06:01 PM   #2
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Last edited by AMSMIKE; 03-05-12 at 06:09 PM.
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Old 03-05-12, 06:03 PM   #3
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finished plumbing all the lines.





Last edited by AMSMIKE; 03-06-12 at 05:01 PM.
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Old 03-06-12, 05:03 PM   #4
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everything is done. updated pictures above.

tomorrow bleed the lines
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Old 03-07-12, 06:53 AM   #5
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Awesome! How's it feel, have you taken it out yet?
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Old 03-07-12, 08:07 AM   #6
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damn it. i should have waited!!!!!!!!!
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Old 03-21-12, 10:11 AM   #7
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another one done yesterday!

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Old 06-08-12, 11:05 PM   #8
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Sick!!! I love it! Gonna try this now!
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Old 06-08-12, 11:17 PM   #9
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the stock unit looks 1 1/4" longer, how did you make the new one fit? Did you weld on extension?
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Old 06-09-12, 08:53 AM   #10
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Quote:
Originally Posted by speedaddic View Post
the stock unit looks 1 1/4" longer, how did you make the new one fit? Did you weld on extension?
Yeah, the piston extension to reach the pedal is what he is showing in this pic.

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Old 06-09-12, 02:02 PM   #11
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Quote:
Originally Posted by speedaddic View Post
the stock unit looks 1 1/4" longer, how did you make the new one fit? Did you weld on extension?
Quote:
Originally Posted by 99 GS3 View Post
Yeah, the piston extension to reach the pedal is what he is showing in this pic.
correct
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Old 06-09-12, 03:30 PM   #12
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what degree double flare is that? 37?
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Old 06-09-12, 06:54 PM   #13
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Quote:
Originally Posted by speedaddic View Post
what degree double flare is that? 37?
45 deg double flare
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Old 06-10-12, 10:39 AM   #14
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Thanks for the info Mike! I just happen to have a snap on 45 degree double flare tool I never used.
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Old 06-11-12, 10:50 PM   #15
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Quote:
Originally Posted by speedaddic View Post
Thanks for the info Mike! I just happen to have a snap on 45 degree double flare tool I never used.
that's exactly what i used to make the lines.
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