LEXUS ES300 2005 Repair Manual

3305L-02
C90470
Turn
Buckle
C90464
C90464
33-14
- PARKING BRAKEPARKING BRAKE CABLE ASSY NO.4
2510 Author
: Date
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
PARKING BRAKE CABLE ASSY NO.4
REPLACEMENT
HINT:
COMPONENTS: See page 71-8 and 33-3
1. REMOVE CONSOLE PANEL UPPER REAR(See page 71-1 1)
2. REMOVE CONSOLE BOX CARPET
3. REMOVE RR CONSOLE BOX(See page 71-1 1)
4. REMOVE CONSOLE BOX MOUNTING BRACKET NO.2
(a) Remove the 2 bolts and console box mounting bracket No.2.
5. REMOVE YAWRATE SENSOR (W/ VSC)(See page 32-59)
6. REMOVE PARKING BRAKE CABLE ASSY NO.4
(a) Loosen the turn buckle, disconnect the parking brake
cable assy No.4 from the parking brake cable assy No.1.
(b) Disconnect the parking brake cable assy No.4 from the
parking brake equalizer.
(c) Remove the 2 bolts and parking brake cable assy No.4.
7. INSTALL PARKING BRAKE CABLE ASSY NO.4
(a) Install the parking brake cable No.4 with the 2 bolts.
Torque: 12.5 NVm (128 kgfVcm, 9 ftVlbf)
(b) Connect the parking brake cable assy No.4 to the parking
brake equalizer.

C90470
Turn
Buckle
- PARKING BRAKEPARKING BRAKE CABLE ASSY NO.4
33-15
2511 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(c) Tighten the turn buckle, connect the parking brake cable
assy No.4 to the parking brake cable assy No.1.
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
8. INSTALL YAWRATE SENSOR (W/ VSC)(See page 32-59)
9. INSTALL CONSOLE BOX MOUNTING BRACKET NO.2
(a) Install the console box mounting bracket No.2 with the 2 bolts.
Torque: 12.5 NVm (128 kgfVcm, 9 ftVlbf)
10. INSTALL RR CONSOLE BOX
11. INSTALL CONSOLE BOX CARPET
12. INSTALL CONSOLE PANEL UPPER REAR
13. INSPECT AND ADJUST PARKING BRAKE PEDAL TRAVEL
14. CHECK VSC SENSOR SIGNAL (W/ VSC)(See page 05-471)

3305M-03
C64523
Contract
F06409
F40318
33-16
- PARKING BRAKEPARKING BRAKE ASSY
2512 Author
: Date
:
PARKING BRAKE ASSY
OVERHAUL
HINT:

COMPONENTS: See page 33-3

Overhaul the RH side by the same procedures with LH side.
1. REMOVE REAR WHEEL
2. REMOVE REAR DISC BRAKE CALIPER ASSY LH
(a) Remove the 2 bolts and separate the rear disc brake caliper assy LH.
HINT:
Do not disconnect the flexible hose from the brake caliper.
3. REMOVE REAR DISC
(a) Release the parking brake, and remove the rear disc.
HINT:

Put matchmarks on the disc and the axle hub.

If the disc cannot be removed easily, turn the shoe adjust-
er until the wheel turns freely.
4. INSPECT BRAKE DISC INSIDE DIAMETER
(a) Using a brake drum gauge or equivalent, measure the in-
side diameter of the disc.
Standard inside diameter: 170 mm (6.69 in.)
Maximum inside diameter: 171 mm (6.73 in.)
5. REMOVE PARKING BRAKE SHOE RETURN TENSION
SPRING
(a) Using a needle-nose pliers, remove the 2 return tension
springs.
6. REMOVE PARKING BRAKE SHOE STRUT COMPRESSION SPRING
(a) Slide out the front shoe and remove the compression spring.
7. REMOVE PARKING BRAKE SHOE STRUT LH

F40319
F40320
BR5332
BR0828
- PARKING BRAKEPARKING BRAKE ASSY
33-17
2513 Author
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:
8. REMOVE PARKING BRAKE SHOE
(a) Release the cup claw and remove the front and rear park-
ing brake shoe.
(b) Disconnect the parking brake cable from the shoe lever.
(c) Remove the tension spring and shoe adjuster screw set
from the front and rear shoe.
(d) Remove the 2 shoe hold-down springs, 4 cups and 2
pins.
(e) Using a screwdriver, remove the C-washer.
(f) Remove the shim and shoe lever from the parking brake
shoe.
9. INSPECT PARKING BRAKE SHOE LINING
THICKNESS
(a) Using a ruler, measure the thickness of the shoe lining.
Standard thickness: 2.0 mm (0.079 in.)
Minimum thickness: 1.0 mm (0.039 in.)
If the lining thickness is at the minimum thickness or less, or if
there is severe, uneven wear, replace the brake shoe.
10. INSPECT BRAKE DISC AND PARKING BRAKE SHOE
LINING FOR PROPER CONTACT
(a) Apply chalk to the inside surface of the disc, then grind
down the brake shoe lining to fit.
If the contact between the brake disc and the shoe lining is im-
proper, repair it using a brake shoe grinder or replace the brake
shoe assembly.
11. APPLICATION HIGH TEMPERATURE GREASE
(a) Apply the high temperature grease to the shoe attached surface of backing plate.

R00343
C80705
F40318
33-18
- PARKING BRAKEPARKING BRAKE ASSY
2514 Author
: Date
:
12. INSTALL PARKING BRAKE SHOE
(a) Install the shoe lever and shim to the rear shoe with a new
C-washer .
(b) Using a feeler gauge, measure the clearance.
Standard clearance: Less than 0.35 mm (0.0138 in.)
If the clearance is not within the specification, replace the shim
with one of the correct size.
Shim ThicknessShim Thickness
0.3 mm (0.012 in.)0.9 mm (0.035 in.)
0.6 mm (0.024 in.)-
(c) Apply the high temperature grease to the adjusting bolt.
(d) Install the shoe adjusting screw set and tension spring to
the front and rear shoe.
(e) Install the 2 pins, 4 cups and 2 shoe hold-down springs.
(f) Connect the parking brake cable to the shoe lever.
(g) Install the front and rear parking brake shoe.
13. INSTALL PARKING BRAKE SHOE STRUT LH
14. INSTALL PARKING BRAKE SHOE STRUT COMPRESSION SPRING
15. INSTALL PARKING BRAKE SHOE RETURN TENSION
SPRING
(a) Using a needle nose pliers, install the 2 return tension
springs.

F40322
Front FrontRH
LH
F40026
Expand
Contract
- PARKING BRAKEPARKING BRAKE ASSY
33-19
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16. CHECK PARKING BRAKE INSTALLATION
(a) Check that each part is installed properly.
NOTICE:
There should be no oil or grease adhering to the friction surface of the shoe lining and disc.
17. INSTALL REAR DISC(See page 32-41)
18. ADJUST PARKING BRAKE SHOE CLEARANCE
(a) Temporarily install the hub nuts.
(b) Remove the hole plug, and turn the adjuster and expand
the shoes until the disc locks.
(c) Contract the shoe adjuster until the disc can rotate
smoothly.
Standard : Return 8 notches
(d) Check shoe is no brake drag.
(e) Install the hole plug.
19. INSTALL REAR DISC BRAKE CALIPER ASSY LH
(a) Install the rear disc brake caliper with the 2 bolts.
Torque: 47 NVm (480 kgfVcm, 35 ftVlbf)
20. INSTALL REAR WHEEL
Torque: 103 NVm (1,050 kgfVcm, 76 ftVlbf)
21. INSPECT AND ADJUST PARKING BRAKE PEDAL TRAVEL(See page 33-2)

3305F-02
- PARKING BRAKEPARKING BRAKE SYSTEM
33-1
2497 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
PARKING BRAKE SYSTEM
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
Brake drag
1. Parking brake pedal or lever travel (Out of adjustment)
2. Parking brake wire (Sticking)
3. Parking brake shoe clearance (Out of adjustment)
4. Parking brake shoe lining (Cracked or distorted)
5. Tension or return spring (Damaged)33-2
33-8
33-1 1
33-14
33-16
33-16
33-16

3305G-02
F41011
Adjusting Nut
Lock Nut 33-2
- PARKING BRAKEPARKING BRAKE SYSTEM
2498 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
ADJUSTMENT
1. REMOVE REAR WHEEL
2. ADJUST PARKING BRAKE SHOE CLEARANCE(See page 33-16)
3. INSTALL REAR WHEEL
Torque: 103 NVm (1,050 kgfVcm, 76 ftVlbf)
4. INSPECT PARKING BRAKE PEDAL TRAVEL
(a) Slowly depress the parking brake pedal all the way, and count the number of clicks.
Parking brake pedal travel: 3 - 6 clicks at 300 N (31 kgf, 68.3 lbf)
5. ADJUST PARKING BRAKE PEDAL TRAVEL
(a) Depress the parking brake pedal 3 notches to make a
room for the procedure, and loosen the lock nut.
(b) Return the parking brake pedal to the original position.
(c) Turn the adjusting nut until the parking brake pedal travel
is correct.
(d) Depress the parking brake pedal 3 notches to make a
room for the procedure, and tighten the lock nut.
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
(e) Return the parking brake pedal to the original position.
(f) Check whether parking brake drags or not.
(g) When operating the parking brake pedal, check that the
parking brake pedal indicator light lights up.

3305H-02
F41008NVm (kgfVcm, ftVlbf) : Specified torque
39 (398, 29)
5.4 (55, 48 in.Vlbf)
Lock NutAdjusting NutParking Brake Control Pedal Assy
Parking Brake Switch Assy
Tension Spring
Parking Brake Cable Assy No.1
Clip
39 (398, 29)39 (398, 29)
Parking Brake Control Pedal Assy:
Parking Pedal PadReturn Spring Damper
- PARKING BRAKEPARKING BRAKE
33-3
2499 Author
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:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
PARKING BRAKE
COMPONENTS

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
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)