Lexus ES300 1992 Chassis

SECTION 6 – 3
173
SERVICE PROCEDURES AND
SPECIFICATIONS
Chassis
Specifications174 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking clutch pedal freeplay176 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking brake and clutch fluids176 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking brake pedal freeplay177 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking brake pedal clearance178 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking parking brake adjustment178 . . . . . . . . . . . . . . . . . . . . . . . .
Checking the brake booster179 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking power steering fluid179 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking steering wheel freeplay180 . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking automatic transmission fluid181 . . . . . . . . . . . . . . . . . . . . . .
Checking lire pressure182 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotating tires183 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking and replacing tires184 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing snow tires and chains186 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing wheels187 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Aluminum wheel precautions187 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHASSIS
174
SPECIFICATIONS
− MANUAL TRANSAXLE
Oil capacity
Oil type
Recommended oil viscosity
4.2 L (4.4 qt., 3.7 Imp.qt.)
Multipurpose gear oil API GL-5
SAE 75 W − 90
− AUTOMATIC TRANSMISSION
Fluid capacity
Dry fill
Drain and refill
Fluid type
6.5 L (6.8 qt., 5.7 Imp.qt.)
3.1 L (3.3 qt., 2.7 Imp.qt.)
Automatic transmission fluid DEXRON
®-II
− DIFFERENTIAL (Automatic transmission)
Fluid capacity
Fluid type:
0.8 L (0.8 qt., 0.7 Imp.qt.)
Automatic transmission fluid DEXRON®-II
− CLUTCHES
Pedal freeplay
Fluid type
5 − 15 mm (0.2 − 0.6 in.)
FMVSS No. 116 DOT 3 or SAE J1703
− BRAKES
Minimum pedal clearance when depressed,
Pedal freeplay
Pad wear limit
Parking brake lining wear limit
Parking brake adjustment
Fluid type
70 mm (2.8 in.) Min.
1 − 6 mm (0.04 − 0.24 in.)
1.0 mm (0.04 in.)
1.0 mm (0.04 in.)
5 − 8 clicks
SAE J1703 or FMVSS No. 116 DOT 3

CHASSIS
175 − STEERING
Wheel freeplay
Power steering fluid type
Less than 30 mm (1.2 in.)
Automatic transmission fluid DEXRON®-II
− TIRES AND WHEELS
Tire size
Recommended cold tire inflation pressure:
Vehicle load up to 4 occupants
Vehicle load up to vehicle capacity weight
Spare tire
Trailer towing (conventional and snow tires)
Wheel size
Standard tire
Spare tire
Wheel nut torque
P205/65 R15 92V or P205/65 R15 AS 92V
180 kPa (1.8 kg/cm
2, 26 psi) (Both front and rear)
220 kPa (2.2 kg/cm2, 32 psi) (Both front and rear)
220 kPa (2.2 kg/cm2, 32 psi)
220 kPa (2.2 kg/cm2, 32 psi) (Both front and rear)
15 x 6 JJ (aluminum wheels)
15 x 6 JJ (steel wheel)
103 N.m (10.5 kgf-m, 76 ft-Ib)

CHASSIS
176
CHECKING CLUTCH PEDAL
FREEPLAY
5 - 15 mm
(0.2 - 0.6 in.)
Press down lightly on the clutch pedal and measure the
distance it moves freely before the clutch resistance is
felt. The freeplay should be within the above limits.
If the freeplay is more or less, have your Lexus dealer inspect
the clutch.
CHECKING BRAKE AND
CLUTCH FLUIDS
Maximum level line
Brake fluid reservoir
Clutch fluid reservoir
Maximum level line
To check the fluid levels, simply look at the see-through
reservoirs. The brake and clutch fluid levels should be
between the “MAX” and “MIN” lines on the tanks.

CHASSIS
177 It is normal for the brake fluid level to go down slightly as the
brake pads wear. So be sure to keep the reservoir filled.
If any reservoir needs frequent refilling, it may indicate a
serious mechanical problem.
If the level is low, add FMVSS No. 116 DOT 3 or SAE J1703
brake fluid to the brake or clutch reservoir.
Remove and replace the reservoir cover by hand. Add brake
fluid up to the line.
Use only newly opened brake fluid. Once opened, brake fluid
absorbs moisture from the air, and excess moisture can cause
a dangerous loss of braking.
CAUTION:
Take care when filling the reservoirs because brake fluid
can harm your eyes and damage painted surfaces. If fluid
gets in your eyes, flush your eyes with clean water.
NOTICE:
If you spill some of the fluid, be sure to wash it off with
water to prevent it from damaging the parts or
paintwork.
CHECKING BRAKE PEDAL
FREEPLAY
1 - 6 mm
(0.04 - 0.24 in.)
With the engine stopped, first reduce the vacuum in the
booster by depressing the brake pedal several times.
Then lightly and slowly press down on the pedal with your
fingers and measure the distance it moves before slight
resistance is felt.
If the freeplay is more or less than specification, have your
Lexus dealer adjust the brakes.

CHASSIS
178
CHECKING BRAKE PEDAL
CLEARANCE
70 mm (2.8 in.) Min.
With the engine running, have someone press the brake
pedal several times and then press hard (approximately
490 N [50 kgf, 110 lb.]) on it. The distance from the asphalt
sheet to the top surface of the pedal should not be less
than specified.
If the clearance is less, your Lexus dealer should adjust the
brakes.
CHECKING PARKING BRAKE
ADJUSTMENT
5 - 8 clicks
Count the number of clicks as you slowly pull up the
parking brake as far as it will go (approximately 196 N [20
kgf, 44 lb.]). The adjustment is correct if you hear 5 to 8
clicks.
If you count more or less clicks, have the parking brake
adjusted by your Lexus dealer.

CHASSIS
179
CHECKING THE BRAKE
BOOSTER
Sit in the driver’s seat and follow the instructions given
below. If your brakes do not operate as described, have
them checked at your Lexus dealer.
1. With the engine stopped, depress the brake pedal several
times: the travel distance should not change.
2. With the brake fully depressed, start the engine: the pedal
should move down a little when the engine starts.
3. Depress the brake, stop the engine, and hold the pedal in
for about 30 seconds: the pedal should sink slightly when the
engine stops. Afterward, the pedal should neither sink nor rise.
4. Restart the engine, run it for about a minute and turn it off.
Then firmly depress the brake several times: the pedal travel
should decrease with each application.
CHECKING POWER STEERING
FLUID
Power steering
fluid reservoir
Check the fluid level through the reservoir. If necessary,
add DEXRON®-II automatic transmission fluid.
If the vehicle has been driven around 80 km/h (50 mph) for 20
minutes (a little more in frigid temperatures), the fluid is hot
(60
C − 80
C or 140
F − 175
F). You may also check the level
when the fluid is cold (about room temperature, 10
C − 30
C
or 50
F − 85
F) if the engine has not been run for about five
hours.

CHASSIS
180
If hot O.K.
If hot add
If cold O.K.
If cold add
Clean all dirt from outside of the reservoir tank and look at the
fluid level. If the fluid is cold, the level should be in the “COLD”
range. Similarly, if it is hot, the fluid level should be in the “HOT”
range. If the level is at the low side of the appropriate range,
add DEXRON
®-II automatic transmission fluid to bring the
level within the range.
To remove the filler cap, turn it counterclockwise and lift up. To
reinstall it, turn it clockwise. After replacing the filler cap,
visually check the steering box case, vane pump and hose
connections for leaks or damage.
CAUTION:
The reservoir tank may be hot so be careful not to burn
yourself.
NOTICE:
Avoid overfilling, or the power steering could be
damaged.
CHECKING STEERING WHEEL
FREEPLAY
30 mm (1.2 in.)
max.
With the vehicle stopped and the front wheels pointed
straight ahead, rock the steering wheel gently back and
forth. If the freeplay is more than specified, have it
inspected by your Lexus dealer.
Use only a very light finger pressure to rock the wheel slowly.

CHASSIS
181
CHECKING AUTOMATIC
TRANSMISSION FLUID
1. Check the fluid level only when the transmission is at
normal operating temperature. With the vehicle level, first
set the parking brake and then start the engine. While the
engine is idling, depress the brake pedal and shift the
selector lever into each range from “P” to “L” and return
to “P”.
If the vehicle has been driven over 16 km or 10 miles (24 km
or 15 miles in frigid temperatures) and the fluid temperature is
70
C − 80
C (160
F − 175
F), the transmission is at normal
operating temperature.
You may check the level when the transmission is cold. If the
vehicle has not been driven for over five hours and the fluid is
about room temperature 20
C − 30
C (70
F − 85
F), the
transmission is cold.
However, checking a cold transmission is to be used for your
reference only and the transmission must be checked again for
correct level at normal operating temperature.
If the vehicle has just been driven for a long time at high speed,
in city traffic in hot weather, or the vehicle has been pulling a
trailer, an accurate fluid level cannot be obtained. Check the
level after the fluid has cooled down (about 30 minutes.)
2. With the engine still idling, check the fluid level and
condition on the dipstick. If necessary, add DEXRON®-II
automatic transmission fluid.
a. Release the clips, pull the dipstick out and wipe it clean.
b. Reinsert the dipstick−push it in as far as it will go.

CHASSIS
182
If cold
addIf cold
O.K.
If hot
addIf hot
O.K.
c. Pull the dipstick out and look at the fluid level. If the
transmission is cold, the level should be in the “COOL” range
on the dipstick. Similarly, if it is hot, the fluid level should be in
the “HOT” range. If the level is at the low side of the appropriate
range, add DEXRON
®-Il automatic transmission fluid to bring
the level within the range. (Fluid is added through the dipstick
tube, using a funnel.)
d. While checking the fluid level, also check the condition. If
the fluid is black or if it smells burnt, have it changed.
CAUTION:
When the engine is running, keep hands and clothing
away from the moving fan and engine drive belt.
Be careful not to touch the hot exhaust manifold.
NOTICE:
Avoid overfilling, or the transmission could be
damaged.
CHECKING TIRE PRESSURE
Label
The recommended cold tire pressures, tire size and the
vehicle capacity weight are given on the label inside the
glovebox lid.
You should check the tire pressures every two weeks, or at
least once a month. And don’t forget the spare! The air
pressure for the spare tire should be 40 kPa (0.4 kg/cm
2, 6 psi)
above the recommended cold tire pressure. Incorrect tire
pressure can reduce tire life and make your vehicle less safe
to drive.
Low tire pressure results in excessive wear, poor handling,
reduced fuel economy, and the possibility of blowouts from
overheated tires. Also, low tire pressure can cause poor
sealing of the tire bead. If the tire pressure is excessively low,
there is the possibility of wheel deformation and/or tire
separation. So keep your tire pressures at the proper level. If
a tire needs frequent refilling, have it checked by your Lexus
dealer.