LEXUS LS430 2003 Factory Repair Manual

Fig. 44: Removing Snap Ring With Snap Ring Pliers
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
d. Place a shop rag and 2 wooden blocks on the work table, and lightly tap the cylinder flange against
the block edges until the No.2 piston drops out of the cylinder.
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HINT:
Make sure that the distance (A) from the shop rag to the top of the blocks is at least 100 mm (3.94
in.).
e. Remove the O-rin
g from the master cylinder body.

Fig. 45: Removing No.2 Piston From Cylinder
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
9.INSTALL BRAKE MASTER CYLINDER KIT
a. Place the brake master cylinder sub-assy in a vise.
b. Apply lithium soap base glycol grease to new No.1 piston sub-assy and No.2 piston sub-assy.
c. Using a flat tip driver, insert the No.2 piston sub-assy horizontally and insert the master cylinder
straight.
d. Install the No.1 piston sub-assy straight.

Fig. 46: Inserting No.2 Piston Sub-Assy
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
e. Push in the piston by hand and install the snap ring using snap ring pliers.
f. Apply lithium soap base glycol grease to a new O-ring and install the O-ring to the master cylinder.

Fig. 47: Installing Snap Ring
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
10.INSTALL MASTER CYLINDER RESERVOIR GROMMET
a. Apply lithium soap base glycol grease to the 2 master cylinder reservoir grommets.
b. Install the 2 master cylinder reservoir grommets to the master cylinder reservoir sub-assy.
11.INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSY
a. Install the master cylinder reservoir sub-assy to the master cylinder sub-assy with the set screw.
b. Install the master cylinder reservoir strainer and master cylinder reservoir filler cap.
c. Connect the brake fluid warning switch connector.
12.INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD
a. Depress the brake pedal several times while the engine is stopped to release the pressure.
b. Set SST on the brake master cylinder sub-assy and lower the pin of the SST until it slightly touches
the piston.
c. Apply chalk to the flat surfaced tip of the SST pin.
SST 09737-00013

Fig. 48: Applying Chalk To Flat Surfaced Tip Of SST Pin
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
d. Turn SST upside down and place it on brake booster assy. Measure the clearance between the brake
booster assy and SST.
Clearance: 0 mm (0 in.)

Fig. 49: Measuring Clearance Between Brake Booster Assy And SST (1 Of 2)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
HINT:
If there is a clearance between the SST main body and the shell of the brake booster assy (floating
SST main body), the push rod is protruding too far.
If the chalk does not stick on the brake booster push rod, the push rod protrusion is insufficient.
Adjust the clearance if either of the above conditions is detected.

Fig. 50: Measuring Clearance Between Brake Booster Assy And SST (2 Of 2)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Using SST, adjust the booster push rod length until the push rod lightly touches the pin head.
SST 09737-00020
Fig. 51: Adjusting Booster Push Rod Length

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
13.INSTALL BRAKE MASTER CYLINDER SUB-ASSY
a. Install the brake master cylinder sub-assy and vacuum check valve bracket with 2 nuts.
Torque: 13 N.m (130 kgf.cm, 9 ft.lbf)
b. Connect the brake fluid level warning switch connector to the master cylinder reservoir.

Fig. 52: Installing Brake Master Cylinder Sub-Assy And Vacuum Check Valve Bracket With
Nuts
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
c. Using SST, install the brake tube to the brake master cylinder sub-assy and ABS & TRACTION
actuator assy.
SST 09751-36011
Torque: 15 N.m (155 kgf.cm, 11 ft.lbf)
d. Install the clamp.

Fig. 53: Installing Brake Tube To Brake Master Cylinder Sub-Assy And ABS & TRACTION
Actuator Assy
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
14.FILL RESERVOIR WITH BRAKE FLUID
15.BLEED MASTER CYLINDER (SEE BLEEDING
)
16.BLEED BRAKE LINE (SEE BLEEDING
)
17.CHECK FLUID LEVEL IN RESERVOIR
18.CHECK FOR BRAKE FLUID LEAKAGE
If fluid leaks, tighten or replace the leaking part.
19.INSTALL ENGINE ROOM NO.3 R/B
a. Install the engine room No.3 R/B with a bolt.
20.INSTALL ENGINE ROOM SIDE COVER
COMPONENTS