brake LEXUS ES300 2005 Manual PDF
[x] Cancel search | Manufacturer: LEXUS, Model Year: 2005, Model line: ES300, Model: LEXUS ES300 2005Pages: 969, PDF Size: 24.08 MB
Page 277 of 969
F41533Disc brake grease Lithium soap base glycol grease
Non-reusable part
NVm (kgfVcm, ftVlbf)
: Specified torque Front Disc Brake
Bleeder Plug
Front Flexible Hose Union Bolt
Gasket
Front Disc Brake
Bleeder Plug Cap
Front Disc Brake
Cylinder Slide Pin
Front Disc Brake
Cylinder Slide Bush
Front Disc Brake
Bush Dust Boot
Front Disc Brake
Bush Dust Boot
Front Disc Brake
Cylinder Slide Pin
Front Disc Brake
Cylinder Mounting LH
Front Disc Brake
Pad Support Plate
Front Disc
Anti Squeal
Shim
Disc Brake
Pad Kit Front
Twin Piston Type:
Set Ring
Cylinder Boot Front Disc
Brake Piston
Piston Seal
Disc Brake
Cylinder Assy LH
Anti Squeal
ShimWear Indicator
106.9 (1,090, 79)
106.9 (1,090, 79)
34.3 (350, 25)
8.3 (85, 74 in.Vlbf)
29.4 (300, 22)
34.3 (350, 25)
32-32
- BRAKEFRONT BRAKE
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320E6-04
F41534
F41535
F41536
- BRAKEFRONT BRAKE
32-33
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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.
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F41537
F41561
C68791
F41563
F41564
32-34
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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).
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F41539
F41560
- BRAKEFRONT BRAKE
32-35
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
14. REMOVE FRONT DISC BRAKE PISTON
(a) Remove the front disc brake piston (Single piston Type).
(1) Place a piece of cloth or like, between the piston
and the disc brake cylinder.
(2) Use compressed air to remove the piston from the
disc brake cylinder.
CAUTION:
Do not place your fingers in front of the piston when using
compressed air.
NOTICE:
Do not spatter the brake fluid.
(b) Remove the 2 front disc brake pistons (Twin piston Type).
(1) Place a piece of cloth or like, between the piston
and the disc brake cylinder.
(2) Use compressed air to remove one of the piston
from the disc brake cylinder.
(3) Press the removed piston to the cylinder with a cer-
tain force that prevent the piston from flying out via
a chip of wood. Then blow into the air of compressor
again to remove the other piston.
CAUTION:
Do not place your fingers in front of the piston when using
compressed air.
NOTICE:
Do not spatter the brake fluid.
15. REMOVE PISTON SEAL
(a) Using a screwdriver, remove the piston seal from the disc brake cylinder (Single piston Type).
NOTICE:
Do not damage the inner cylinder and the cylinder groove.
(b) Using a screwdriver, remove the 2 piston seals from the disc brake cylinder (Twin piston Type).
NOTICE:
Do not damage the inner cylinder and the cylinder groove.
16. REMOVE FRONT DISC BRAKE BLEEDER PLUG CAP
17. REMOVE FRONT DISC BRAKE BLEEDER PLUG
18. INSPECT BRAKE CYLINDER AND PISTON
(a) Check the cylinder bore and piston for rust or scoring.
Page 281 of 969
F41541
F41542
F41543
Matchmarks
32-36
- BRAKEFRONT BRAKE
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
19. INSPECT PAD LINING THICKNESS
(a) Using a ruler, measure the pad lining thickness.
Single piston type:
Standard thickness: 12.0 mm (0.472 in.)
Minimum thickness: 1.0 mm (0.039 in.)
Twin piston type:
Standard thickness: 10.6 mm (0.417 in.)
Minimum thickness: 1.0 mm (0.039 in.)
20. INSPECT FRONT DISC BRAKE PAD SUPPORT PLATE
(a) Make sure that they have sufficient rebound, no deformation cracks or wear, and all rust, dirt are
cleaned off.
21. INSPECT FRONT DISC BRAKE PAD SUPPORT PLATE
(a) Make sure that they have sufficient rebound, no deformation cracks or wear, and all rust, dirt are
cleaned off.
22. INSPECT DISC THICKNESS
(a) Using a micrometer, measure the disc thickness.
Standard thickness: 28.0 mm (1.102 in.)
Minimum thickness: 26.0 mm (1.024 in.)
23. REMOVE FRONT DISC
(a) Put matchmarks on the disc and the axle hub.
(b) Remove the disc.
24. INSTALL FRONT DISC
(a) Aligning the matchmarks, install the front disc.
HINT:
When replacing the disc with a new one, select the installation position where the disc has the minimum run-
out.
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F41544
F41565
- BRAKEFRONT BRAKE
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
25. INSPECT DISC RUNOUT
(a) Temporarily install the disc with hub nuts.
Torque: 103 NVm (1,050 kgfVcm, 76 ftVlbf)
(b) Using a dial indicator, measure the disc runout 10 mm
(0.39 in.) away from the outer edge of the disc.
Maximum disc runout: 0.05 mm (0.0020 in.)
(c) If the disc runout is greater than the maximum value,
check the bearing play in the axial direction and check the
axle hub runout (see page 30-2). If the bearing play and
axle hub runout are normal, adjust the disc runout or grind
it on a ºOn-carº brake lathe.
26. TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG
(a) Temporarily tighten the bleeder plug to the disc brake cylinder.
27. INSTALL FRONT DISC BRAKE BLEEDER PLUG CAP
28. INSTALL PISTON SEAL
(a) Install the piston seal (Single piston Type).
(1) Apply the lithium soap base glycol grease to a new piston seal.
(2) Install the piston seal to the disc brake cylinder.
(b) Install the 2 piston seals (Twin piston Type).
(1) Apply the lithium soap base glycol grease to the 2 new piston seals.
(2) Install the 2 piston seals to the disc brake cylinder.
29. INSTALL FRONT DISC BRAKE PISTON
(a) Install the front disc brake piston (Single piston Type).
(1) Apply the lithium soap base glycol grease to the piston.
(2) Install the piston to the disc brake cylinder.
NOTICE:
Do not screw the piston forcibly into the disc brake cylinder.
(b) Install the 2 front disc brake pistons (Twin piston Type).
(1) Apply the lithium soap base glycol grease to the 2 pistons.
(2) Install the 2 pistons to the disc brake cylinder.
NOTICE:
Do not screw the piston forcibly into the disc brake cylinder.
30. INSTALL CYLINDER BOOT
(a) Install the cylinder boot (Single piston Type).
(1) Apply the lithium soap base glycol grease to a new
cylinder boot.
(2) Install the cylinder boot to the disc brake cylinder.
HINT:
Install the boot securely to the grooves of the cylinder and pis-
ton.
(3) Using a screwdriver, install a new set ring.
NOTICE:
Do not damage the cylinder boot.
Page 283 of 969
F41566
C68792
F41703
Anti squeal
Shim No.1
Anti squeal
Shim No.2
Anti squeal
Shim No.1
Wear Indicator
32-38
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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.
Page 284 of 969
F41866
Anti Squeal
Shim
Wear Indicator
- BRAKEFRONT BRAKE
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(2) 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.
(b) Install the anti squeal shim kit front (Twin piston Type).
(1) Apply the anti squeal shim with pad grease, and
install the anti squeal shim to each pad.
(2) 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.
38. INSTALL DISC BRAKE PAD KIT FRONT (PAD ONLY)
(a) Install the 2 disc brake pads with the pad wear indicator facing upward.
NOTICE:
There should be no oil or grease on the friction surface of the pads and the disc.
39. INSTALL DISC BRAKE CYLINDER ASSY LH
(a) Install the disc brake cylinder with the 2 bolts.
Torque: 34.3 NVm (350 kgfVcm, 25 ftVlbf)
40. CONNECT FRONT 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 hold of the disc brake cylinder.
41. FILL RESERVOIR WITH BRAKE FLUID
42. BLEED MASTER CYLINDER (SEE PAGE 32-4)
SST 09023-00101
43. BLEED BRAKE LINE (SEE PAGE 32-4)
44. CHECK FLUID LEVEL IN RESERVOIR (SEE PAGE 32-4)
45. CHECK BRAKE FLUID LEAKAGE
46. INSTALL FRONT WHEEL
Torque: 103 NVm (1,050 kgfVcm, 76 ftVlbf)
Page 285 of 969
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
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
REAR BRAKE
COMPONENTS
Page 286 of 969
320E8-04
F41547
F41548
F41550
- BRAKEREAR BRAKE
32-41
2475 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
OVERHAUL
HINT:
Overhaul the RH side by the same procedures with LH side.
Two types of brake pad exist; one is with slit and the other without slit.
1. REMOVE REAR WHEEL
2. DRAIN BRAKE FLUID
NOTICE:
Wash the brake fluid off immediately if it comes into contact with any painted surfaces.
3. DISCONNECT REAR LH 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 REAR DISC BRAKE CYLINDER SLIDE PIN
(a) Remove the rear disc brake cylinder slide pin.
5. REMOVE DISC BRAKE CYLINDER ASSY REAR LH
(a) Lift up the disc brake cylinder and remove the disc brake
cylinder.
6. REMOVE REAR DISC BRAKE CYLINDER SLIDE
BUSH
(a) Remove the cylinder slide bush from the disc brake cylin-
der.