LEXUS LS430 2003 Factory Repair Manual

Fig. 64: Removing Vacuum Check Valve Assy And Grommet From Brake Booster Assy
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
17.INSTALL BRAKE BOOSTER ASSY
a. Install a new brake booster gasket.
b. Install the brake booster assy with the 4 nuts.
Torque: 13 N.m (130 kgf.cm, 9 ft.lbf)

Fig. 65: Installing Brake Booster Assy With Nuts
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
c. Connect the vacuum hose assy to the vacuum check valve assy and set the clip.

Fig. 66: Connecting Vacuum Hose Assy To Vacuum Check Valve Assy And Set Clip
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
18.INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS
a. Install the clevis lock nut and the brake master cylinder push rod clevis.
HINT:
After adjusting the brake pedal height, torque the clevis lock nut.
b. Apply lithium soap base glycol grease to the push rod pin.
c. Install the push rod pin and clip.

Fig. 67: Installing Push Rod Pin And Clip
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
19.INSTALL BRAKE PEDAL RETURN SPRING
a. Install the brake pedal return spring.
20.INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD (SEE OVERHAUL
)
SST 09737-00013
21.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. 68: 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 tubes 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. 69: Installing Brake Tubes To Brake Master Cylinder Sub-Assy And ABS & TRACTION
Actuator Assy
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
22.FILL RESERVOIR WITH BRAKE FLUID (SEE BLEEDING
)
23.BLEED MASTER CYLINDER (SEE BLEEDING
)
24.BLEED BRAKE LINE (SEE BLEEDING
)
25.CHECK FLUID LEVEL IN RESERVOIR (SEE BLEEDING
)
26.CHECK FOR BRAKE FLUID LEAKAGE
27.CHECK AND ADJUST BRAKE PEDAL HEIGHT (SEE ON
-VEHICLE INSPECTION )
28.CHECK PEDAL FREE PLAY (SEE ON
-VEHICLE INSPECTION )
29.CHECK PEDAL RESERVE DISTANCE (SEE ON
-VEHICLE INSPECTION )
30.INSTALL INSTRUMENT PANEL UNDER COVER SUB-ASSY NO.2
31.INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSY NO.1
a. Install the instrument panel under cover sub-assy No.1.
b. Install the 2 bolts and hood lock release lever.
32.INSTALL OUTER MIRROR SWITCH ASSY
33.INSTALL COIN BOX ASSY
34.INSTALL INSTRUMENT PANEL UNDER COVER SUB-ASSY NO.1

35.INSTALL INSTRUMENT CLUSTER FINISH PANEL END
36.INSTALL INSTRUMENT CLUSTER FINISH PANEL CENTER LOWER
37.INSTALL ENGINE ROOM NO.3 R/B
a. Install the engine room No.3 R/B with the bolt and bracket.
38.INSTALL ENGINE ROOM SIDE COVER
COMPONENTS

Fig. 70: Exploded View Of Front Brake
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
OVERHAUL
HINT:
Overhaul the RH side usin
g the same procedures as for the LH side.

1.REMOVE FRONT WHEEL
2.DRAIN BRAKE FLUID
a. Draw out fluid with syringe.
3.REMOVE FRONT DISC BRAKE W/HOLE PIN
a. Remove the clip.
b. Remove the front disc brake anti-rattle w/hole pin while pushing on the anti-rattle spring.
4.REMOVE FRONT DISC BRAKE ANTI-RATTLE SPRING
Fig. 71: Removing Front Disc Brake Anti
-Rattle W/Hole Pin While Pushing On Anti-Rattle Spring
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
5.REMOVE DISC BRAKE PAD KIT FRONT (PAD ONLY)
a. Remove the 2 pads and the 2 anti-squeal shims from each pad.

b. Right wheel:
Remove the clamp, clip and bleeder plug cap, and disconnect the pad wear indicator assembly from the
inner pad.
Fig. 72: Removing Pads And Anti
-Squeal Shims From Pad
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
6.INSPECT PAD LINING THICKNESS
a. Using a ruler, measure the pad lining thickness.
Standard thickness: 11.0 mm (0.433 in.)
Minimum thickness: 1.0 mm (0.039 in.)
If the pad linin
g thickness is less than the minimum, replace the pad.