Mount LEXUS ES300 2005 Owner's Manual

320E6-04
F41534
F41535
F41536
- BRAKEFRONT BRAKE
32-33
2467 Author
: Date
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
OVERHAUL
HINT:
Overhaul the RH side by the same procedures with LH side.
1. REMOVE FRONT WHEEL
2. DRAIN BRAKE FLUID
NOTICE:
Wash the brake fluid off immediately if it comes into contact with any painted surfaces.
3. DISCONNECT FRONT FLEXIBLE HOSE
(a) Remove the union bolt and a gasket from the disc brake cylinder, then disconnect the flexible hose
from the disc brake cylinder.
4. REMOVE DISC BRAKE CYLINDER ASSY LH
(a) Remove the 2 bolts and disc brake cylinder.
5. REMOVE DISC BRAKE PAD KIT FRONT (PAD ONLY)
(a) Remove the 2 brake pads with anti
squeal shims.
6. REMOVE ANTI SQUEAL SHIM KIT FRONT
(a) Remove the 2 anti squeal shims from 2 brake pads.
(b) Using a screwdriver, remove the wear indicator from 2
brake pads.
7. REMOVE FRONT DISC BRAKE PAD SUPPORT PLATE
(a) Remove the upper side front disc brake pad support plate.
8. REMOVE FRONT DISC BRAKE PAD SUPPORT PLATE
(a) Remove the bottom side front disc brake pad support plate.
9. REMOVE FRONT DISC BRAKE CYLINDER SLIDE PIN
(a) Remove the 2 cylinder slide pins from the disc brake cylin-
der mounting.

F41537
F41561
C68791
F41563
F41564
32-34
- BRAKEFRONT BRAKE
2468 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
10. REMOVE FRONT DISC BRAKE CYLINDER SLIDE
BUSH
(a) Remove the cylinder slide bush from the cylinder slide
pin.
11. REMOVE FRONT DISC BRAKE CYLINDER
MOUNTING LH
(a) Remove the 2 bolts and disc brake cylinder mounting.
12. REMOVE FRONT DISC BRAKE BUSH DUST BOOT
(a) Place front disc brake cylinder mounting in vise.
(b) Using a screwdriver and hammer, remove the 2 bush dust
boots from the disc brake cylinder mounting.
13. REMOVE CYLINDER BOOT
(a) Using a screwdriver, remove the set ring and cylinder boot
from the disc brake cylinder (Single piston Type).
(b) Using a screwdriver, remove the 2 set rings and 2 cylinder
boots from the disc brake cylinder (Twin piston Type).

F41566
C68792
F41703
Anti squeal
Shim No.1
Anti squeal
Shim No.2
Anti squeal
Shim No.1
Wear Indicator
32-38
- BRAKEFRONT BRAKE
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(b) Install the 2 cylinder boots (Twin piston Type).
(1) Apply the lithium soap base glycol grease to the 2
new cylinder boots.
(2) Install the 2 cylinder boots to the disc brake cylinder.
HINT:
Install the boot securely to the grooves of the cylinder and pis-
ton.
(3) Using a screwdriver, install the 2 new set rings.
NOTICE:
Do not damage the cylinder boot.
31. INSTALL FRONT DISC BRAKE BUSH DUST BOOT
(a) Place front disc brake cylinder mounting in vise.
(b) Apply the lithium soap base glycol grease to seal surface
of 2 new bush dust boots.
(c) Using a socket wrench (19 mm) and hammer, drive the 2
brake bush dust boots into the brake cylinder mounting.
32. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING LH
(a) Install the disc brake cylinder mounting with the 2 bolts.
Torque: 106.9 NVm (1,090 kgfVcm, 79 ftVlbf)
33. INSTALL FRONT DISC BRAKE CYLINDER SLIDE BUSH
(a) Apply the lithium soap base glycol grease to a new cylinder slide bush.
(b) Install the cylinder slide bush to the cylinder slide pin.
34. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN
(a) Apply the lithium soap base glycol grease to the sliding part and the seal surface of the 2 cylinder slide
pins.
(b) Install the 2 cylinder slide pins to the disc brake cylinder mounting.
HINT:
Install the cylinder slide pin with cylinder slide bush into the bottom side.
35. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE
(a) Install the bottom side front disc brake pad support plate.
36. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE
(a) Install the upper side front disc brake pad support plate.
37. INSTALL ANTI SQUEAL SHIM KIT FRONT
(a) Install the anti squeal shim kit front (Single piston Type).
(1) Apply the both sides of anti squeal shim No.1 with
pad grease, and install the shim together with anti
squeal shim No.2 to each pad.

320E7-03
F41864Disc brake grease Lithium soap base glycol grease
Non-reusable part


NVm (kgfVcm, ftVlbf)
: Specified torque Rear LH
Flexible Hose Union Bolt

Gasket
Rear Disc Brake
Cylinder Slide Pin
Rear Disc Brake
Cylinder Slide Bush
Rear Disc Brake
Bleeder Plug
Rear Disc Brake
Bleeder Plug Cap
Disc Brake Cylinder
Assy Rear LH

Piston Seal
Rear Disc Brake
Disc Brake Piston

Cylinder Boot

Set Ring
Rear Disc Brake
Bush Dust Boot
Rear Disc Brake
Cylinder Slide Pin
Rear Disc Brake
Pad Support Plate
Rear Disc Brake
Cylinder Mounting LH
Anti Squeal
Shim No.1
Disc Brake
Pad Kit Rear Disc Brake
Pad Kit Rear
Parking Brake Shoe
Adjusting Hole Plug
Rear DiscAnti Squeal
Shim No.2 Wear Indicator Anti Squeal
Shim No.2
Anti Squeal
Shim No.1
Wear Indicator



61.8 (630, 46)
61.8 (630, 46)
39.2 (400, 29)
29.4 (300, 22)
34.3 (350, 25)
8.3 (85, 74 in.Vlbf)
32-40
- BRAKEREAR BRAKE
2474 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
REAR BRAKE
COMPONENTS

F41549
F41551
F41535
F41552
32-42
- BRAKEREAR BRAKE
2476 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
7. REMOVE REAR DISC BRAKE BUSH DUST BOOT
(a) Remove the bush dust boot from the cylinder slide pin.
8. REMOVE REAR DISC BRAKE CYLINDER SLIDE PIN
(a) Using a hexagon wrench (8 mm), remove the cylinder
slide pin.
9. REMOVE DISC BRAKE PAD KIT REAR (PAD ONLY)
(a) Remove the 2 brake pads with anti squeal shims.
10. REMOVE REAR DISC BRAKE ANTI SQUEAL SHIM KIT
(a) Remove the 2 anti squeal shims from 2 brake pads.
(b) Using a screwdriver, remove the wear indicator from 2
brake pads.
11. REMOVE REAR DISC BRAKE PAD SUPPORT PLATE
(a) Remove the upper side rear disc brake pad support plate.
12. REMOVE REAR DISC BRAKE PAD SUPPORT PLATE
(a) Remove the bottom side rear disc brake pad support plate.
13. REMOVE REAR DISC BRAKE CYLINDER MOUNTING
LH
(a) Remove the 2 bolts and disc brake cylinder mounting.

F41559
F41865
Anti Squeal
Shim No.2 Anti Squeal
Shim No.2
Anti Squeal
Shim No.1
Anti Squeal
Shim No.1
Wear Indicator
- BRAKEREAR BRAKE
32-45
2479 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
32. INSTALL PISTON SEAL
(a) Apply the lithium soap base glycol grease to a new piston seal.
(b) Install the piston seal to the disc brake cylinder.
33. INSTALL REAR DISC BRAKE PISTON
(a) Apply the lithium soap base glycol grease to the piston.
(b) Install the piston to the disc brake cylinder.
NOTICE:
Do not screw the piston forcibly into the disc brake cylinder.
34. INSTALL CYLINDER BOOT
(a) Apply the lithium soap base glycol grease to a new cylin-
der boot.
(b) Install the cylinder boot to the disc brake cylinder.
HINT:
Install the boot securely to the grooves of the cylinder and pis-
ton.
(c) Using a screwdriver, install a new set ring.
NOTICE:
Do not damage the cylinder boot.
35. INSTALL REAR DISC BRAKE CYLINDER MOUNTING LH
(a) Install the disc brake cylinder mounting with the 2 bolts.
Torque: 61.8 NVm (630 kgfVcm, 46 ftVlbf)
36. INSTALL REAR DISC BRAKE PAD SUPPORT PLATE
(a) Install the bottom side rear disc brake pad support plate.
37. INSTALL REAR DISC BRAKE PAD SUPPORT PLATE
(a) Install the upper side rear disc brake pad support plate.
38. INSTALL REAR DISC BRAKE ANTI SQUEAL SHIM KIT
(a) Apply the both sides of anti squeal shim No.1 with pad
grease, and install the shim together with anti squeal shim
No.2 to each pad.
(b) Install the wear indicator to the 2 brake pads.
NOTICE:

When replacing worn pads, the anti squeal shims
must be replaced together with the pads.

Install the shims and pad wear indicator correctly of
which positions and directions.
39. INSTALL DISC BRAKE PAD KIT REAR (PAD ONLY)
(a) Install the 2 disc brake pads with the pad wear indicator facing downward.
NOTICE:
There should be no oil or grease on the friction surface of the pads and the disc.

F41551
F41562
Cylinder Slide Pin
Cylinder Mounting
Lithium soap base glycol grease
F41558Lithium soap base glycol grease
32-46
- BRAKEREAR BRAKE
2480 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
40. INSTALL REAR DISC BRAKE CYLINDER SLIDE PIN
(a) Using a hexagon wrench (8 mm), install the cylinder slide
pin.
Torque: 39.2 NVm (400 kgfVcm, 29 ftVlbf)
41. INSTALL REAR DISC BRAKE BUSH DUST BOOT
(a) Apply the lithium soap base glycol grease to seal surface
of a new bush dust boot.
(b) Install the bush dust boot to the cylinder slide pin.
42. INSTALL REAR DISC BRAKE CYLINDER SLIDE BUSH
(a) Apply the lithium soap base glycol grease to a new cylin-
der slide bush.
(b) Install the cylinder slide bush to the disc brake cylinder.
43. INSTALL DISC BRAKE CYLINDER ASSY REAR LH
(a) Apply the lithium soap base glycol grease to the cylinder slide pin.
(b) Install the disc brake cylinder to the cylinder slide pin.
44. INSTALL REAR DISC BRAKE CYLINDER SLIDE PIN
(a) Apply the lithium soap base glycol grease to the cylinder slide pin.
(b) Install the cylinder slide pin to the disc brake cylinder.
Torque: 34.3 NVm (350 kgfVcm, 25 ftVlbf)
45. CONNECT REAR LH FLEXIBLE HOSE
(a) Connect a new gasket and flexible hose with the union bolt.
Torque: 29.4 NVm (300 kgfVcm, 22 ftVlbf)
HINT:
Install the flexible hose lock securely in the lock hole of the disc brake cylinder.
46. FILL RESERVOIR WITH BRAKE FLUID
47. BLEED MASTER CYLINDER (SEE PAGE 32-4)
SST 09023-00101
48. BLEED BRAKE LINE (SEE PAGE 32-4)
49. CHECK FLUID LEVEL IN RESERVOIR (SEE PAGE 32-4)
50. CHECK BRAKE FLUID LEAKAGE
51. INSTALL REAR WHEEL
Torque: 103 NVm (1050 kgfVcm, 76 ftVlbf)

F40303
SST
Bolt
SST
F40302
LHRH
F40304
SST
- BRAKESKID CONTROL SENSOR
32-57
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
6. REMOVE SKID CONTROL SENSOR
(a) Mount the rear axle hub in a soft jaw vise.
NOTICE:
Replace the axle hub assembly if it is dropped or a strong
shock is given to it.
(b) Using a pin punch and hammer, drive out the 2 pins and
remove the 2 attachments from SST.
(c) Using SST and 2 bolts (Diameter: 12 mm, pitch: 1.5 mm),
remove the skid control sensor from the rear axle hub.
SST 09520- 00031 (09520- 00040), 09521- 00020,
09950-00020
NOTICE:

If a damage is inflicted to the sensor rotor, replace the
axle hub assembly.

Do not scratch the contacting surface of axle hub and
speed sensor.
7. INSTALL SKID CONTROL SENSOR
(a) Clean the contacting surface of the axle hub and a new
skid control sensor.
NOTICE:
Make sure the sensor rotor is clean.
(b) Place the speed sensor on the axle hub so that the con-
nector is positioned, as shown in the illustration.
(c) Using SST and a press, install the skid control sensor to
the axle hub.
NOTICE:

Do not tap the skid control sensor with a hammer di-
rectly.

Check that the skid control sensor detection part is
clean.

Press in the skid control sensor straight and slowly.
SST 09830- 36010, 09950- 60010 (09951- 00650),
09950-70010 (09951-07100)

C90467F41686
NVm (kgfVcm, ftVlbf) : Specified torque
5.4 (55, 48 in.Vlbf)
12.5 (128, 9)
Consol Box Mounting Bracket No.2Parking Brake Control Pedal Models:
12.5 (128, 9)
Parking Brake EqualizerParking Brake Cable Assy No.3
5.4 (55, 48 in.Vlbf)
5.4 (55, 48 in.Vlbf)7.8 (80, 69 in.Vlbf)
Parking Brake Cable Assy No.4
Parking Brake Cable Heat Insulator
Parking Brake Cable:
5.4 (55, 48 in.Vlbf)
12.5 (128, 9)12.5 (128, 9)
33-4
- PARKING BRAKEPARKING BRAKE
2500 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

3305J-02
C90470
Turn
Buckle
F41010
33-8
- PARKING BRAKEPARKING BRAKE CABLE ASSY NO.1
2504 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
PARKING BRAKE CABLE ASSY NO.1
REPLACEMENT
HINT:
COMPONENTS: See page 71-8 and 33-3
1. REMOVE FRONT DOOR SCUFF PLATE RH
2. REMOVE FRONT DOOR SCUFF PLATE LH
3. REMOVE INSTRUMENT PANEL SUB-ASSY UPPER(See page 71-1 1)
4. REMOVE INSTRUMENT PANEL INSERT SUB-ASSY LOWER LH(See page 71-1 1)
5. REMOVE INSTRUMENT PANEL UNDER COVER SUB-ASSY NO.1(See page 71-1 1)
6. REMOVE INSTRUMENT PANEL SUB-ASSY LOWER(See page 71-1 1)
7. REMOVE CONSOLE PANEL UPPER REAR(See page 71-1 1)
8. REMOVE CONSOLE BOX CARPET
9. REMOVE RR CONSOLE BOX(See page 71-1 1)
10. REMOVE INSTRUMENT PANEL FINISH PANEL END RH
11. REMOVE INSTRUMENT PANEL FINISH PANEL END LH(See page 71-1 1)
12. REMOVE AIR DUCT REAR NO.1
13. REMOVE AIR DUCT REAR NO.2
14. REMOVE CONSOLE BOX DUCT NO.1
15. REMOVE YAWRATE SENSOR (W/ VSC)(See page 32-59)
16. REMOVE PARKING BRAKE CABLE ASSY NO.1
(a) Loosen the turn buckle, disconnect the parking brake
cable assy No.1 from the parking brake cable assy No.4.
(b) Remove the 2 bolts and console box mounting bracket
No.2.
(c) Remove the lock nut, adjusting nut and clip, then discon-
nect the parking brake cable assy No.1 from the parking
brake control pedal assy.