LEXUS GS400 2000 Service Repair Manual

BR0JO±07
± BRAKEFRONT BRAKE CALIPER
BR±23
2131 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
INSTALLATION
Installation is in the reverse order of removal (See page BR±19).
HINT:

After installation, fill the brake reservoir with brake fluid and bleed brake system (See page BR±4).

Check for leaks.

BR0JP±08
F06933
Anti±squeal Shim
Inner Anti±squeal ShimInner PadAnti±squeal Spring
Outer PadInner Anti±squeal Shim
Anti±squeal Shim
Pad Guide Pin
Disc brake grease
Clip
BR±24
± BRAKEREAR BRAKE PAD
2132 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
REAR BRAKE PAD
COMPONENTS

BR0JQ±03
F07245
F04917
A
A B
B
± BRAKEREAR BRAKE PAD
BR±25
2133 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
REPLACEMENT
1. REMOVE REAR WHEEL
Remove the rear wheel and temporarily fasten the disc with the
3 hub nuts.
2. INSPECT PAD LINING THICKNESS
Check the pad thickness through the caliper inspection hole
and replace pads if the thickness is not within the specification.
Minimum thickness: 1.0 mm (0.039 in.)
3. REMOVE ANTI±SQUEAL SPRING AND PAD GUIDE
PIN
(a) Raise the ºBº portion with hand, push up the ºAº portion
and disengage the anti±squeal spring from brake caliper.
(b) Remove the anti±squeal spring.
NOTICE:

Do not deform the clip and anti±squeal spring.

The clip and anti±squeal spring can be used again
provided that they have sufficient rebound, no±de-
formation, cracks or wear, and have had all rust, dirt
and foreign particles cleaned off.
(c) Remove the clip and pad guide pin.
4. REMOVE PADS AND ANTI±SQUEAL SHIMS
(a) Remove the 2 pads.
(b) Remove the 4 anti±squeal shims from each pad.
5. CHECK DISC THICKNESS AND RUNOUT
(See page BR±30)
6. INSTALL NEW PADS
NOTICE:
When replacing worn pads, the anti±squeal shims must be
replaced together with the pads.
(a) Apply disc brake grease to both sides of inner anti±squeal
shims (See page BR±24).

F01635
Direction of disc rotation for
forward movement
F01636
F07232
AB
Claw
BR±26
± BRAKEREAR BRAKE PAD
2134 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
(b) Install the 2 anti±squeal shims on each pad.
HINT:
Make sure the arrows on the inner anti±squeal shims facing to
the direction of disc rotation as shown in the illustration.
(c) Draw out a small amount of brake fluid from the reservoir.
(d) Press in the pistons with a monkey wrench handle or
equivalent.
HINT:

Tape the monkey wrench handle before use.

If the piston is difficult to push in, loosen the bleeder plug
and push in the piston while letting some brake fluid es-
cape.
(e) Install the 2 pads.
7. I N S TA L L PA D G U I D E P I N A N D A N T I ± S Q U E A L
SPRING
(a) Install the pad guide pin and clip.
(b) Install the anti±squeal spring.
HINT:

Ensure that the claw of the anti±squeal spring is raised up
on the caliper securely.

Ensure that there is no gap between the pad guide pin
and anti±squeal spring.

Ensure that ºAº and ºBº portions of anti±squeal spring are
attached to the pad.
8. INSTALL FRONT WHEEL
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
9. DEPRESS BRAKE PEDAL SEVERAL TIMES
10. CHECK THAT FLUID LEVEL IS AT MAX LINE

BR0JR±07
F06932

Gasket Piston
Piston Seal
Brake DiscPad Guide Pin Cylinder Boot Inner Anti±squeal Shim
Non±reusable part
Lithium soap base glycol grease
Disc brake grease
: Specified torque


30 (310, 22)
Set RingAnti±squeal Shim Anti±squeal Spring Anti±squeal Shim
Brake Caliper
Inner Anti±squeal ShimOuter Pad Inner Pad
104 (1,065, 77)
Clip
N´m (kgf´cm, ft´lbf)
± BRAKEREAR BRAKE CALIPER
BR±27
2135 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
REAR BRAKE CALIPER
COMPONENTS

BR0JS±06
F01639
BR±28
± BRAKEREAR BRAKE CALIPER
2136 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
REMOVAL
1. REMOVE REAR WHEEL
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
2. DISCONNECT FLEXIBLE HOSE
Remove the union bolt and gasket from the caliper, then discon-
nect the flexible hose from the caliper. Use a container to catch
brake fluid as it drains out.
Torque: 30 N´m (310 kgf´cm, 22 ft´lbf)
HINT:
At the time of installation, please refer to the following item.
Install the flexible hose lock securely in the lock hole in the cali-
per.
3. REMOVE CALIPER
(a) Remove the 2 installation bolts.
Torque: 104 N´m (1,065 kgf´cm, 77 ft´lbf)
(b) Remove the caliper.
4. REMOVE BRAKE PADS (See page BR±25)
(a) Remove the anti±squeal spring.
(b) Remove the clip and pad guide pin.
(c) Remove the 2 pads with the 4 anti±squeal shims.

BR0JT±03
F01640
Z09008
150 mm
(5.91 in.)50 mm
(1.97 in.)
12 mm
(0.472 in.)
F01641
F01642
± BRAKEREAR BRAKE CALIPER
BR±29
2137 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
DISASSEMBLY
1. REMOVE SET RINGS AND BOOTS
Using a screwdriver, remove the 2 set rings and 2 boots.
2. REMOVE PISTONS FROM CYLINDER
(a) Prepare a wooden plate to hold the pistons.
(b) Place the plate between the pistons and insert a pad on
one side.
(c) Use compressed air to remove the pistons alternately
from the caliper.
CAUTION:
Do not place your fingers in front of the piston when using
compressed air.
3. REMOVE PISTON SEALS
Using a screwdriver, remove the 2 piston seals from the caliper.

BR0JU±07
F01643
F01644
F01645
BR±30
± BRAKEREAR BRAKE CALIPER
2138 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
INSPECTION
1. MEASURE PAD LINING THICKNESS
Using a ruler, measure the pad lining thickness.
Standard thickness: 10.5 mm (0.413 in.)
Minimum thickness: 1.0 mm (0.039 in.)
Replace the pads if the thickness is less than the minimum or
if it shows signs of uneven wear.
2. MEASURE DISC THICKNESS
Using a micrometer, measure the disc thickness.
Standard thickness: 12.0 mm (0.472 in.)
Minimum thickness: 10.5 mm (0.413 in.)
Replace the disc if the thickness of the disc is at the minimum
thickness or less. Replace the disc or grind it on a lathe if it is
badly scored or worn unevenly.
3. MEASURE DISC RUNOUT
Using a dial indicator, measure the disc runout at a position 10
mm (0.394 in.) away from the out side edge.
Maximum disc runout: 0.05 mm (0.0020 in.)
If the disc's runout is maximum value or greater, check the bear-
ing play in the axial direction and check the axle hub runout
(See page SA±44). If the bearing play and axle hub runout are
not abnormal, adjust the disc runout or grind it on a ºOn±Carº
brake lathe.
4. IF NECESSARY, ADJUST DISC RUNOUT
(a) Remove the 3 hub nuts and disc. Turn the disc 1/5 and
reinstall the disc. Install and torque the 3 hub nuts.
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
(b) Remeasure the disc runout. Make a note of the runout
and the disc's position on the hub.
(c) Repeat (b) until the disc has been installed on the 3 re-
maining hub positions.
(d) If the minimum runout recorded in (b) and (c) is less than
0.05 mm (0.0020 in.), install the disc in that position.
(e) If the minimum runout recorded in (b) and (c) is greater
than 0.05 mm (0.0020 in.), replace the disc and repeat
step 3.

BR0JV±04
± BRAKEREAR BRAKE CALIPER
BR±31
2139 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page BR±29).
HINT:
Apply lithium soap base glycol grease to the parts indicated by the arrows (See page BR±27).

BR0JW±04
BR±32
± BRAKEREAR BRAKE CALIPER
2140 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
INSTALLATION
Installation is in the reverse order of removal (See page BR±28).
HINT:

After installation, fill the brake reservoir with brake fluid and bleed brake system (See page BR±4).

Check for leaks.