LEXUS LS430 2003 Factory Repair Manual

Fig. 35: Tightening Brace Bolt And Nuts
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
33.INSTALL PUSH ROD PIN
a. Apply lithium soap base glycol grease to the push rod pin.
b. Place the master cylinder push rod clevis, insert the push rod pin and install the clip.

Fig. 36: Inserting Push Rod Pin
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
c. Install the brake pedal return sprin
g.

Fig. 37: Installing Brake Pedal Return Spring
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
d. Connect the stop lamp switch connector and brake pedal load sensing switch connector.

Fig. 38: Connecting Stop Lamp Switch Connector And Brake Pedal Load Sensing Switch
Connector
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

34.CHECK AND ADJUST BRAKE PEDAL HEIGHT (SEE ON-VEHICLE INSPECTION )
35.CHECK PEDAL FREE PLAY (SEE ON
-VEHICLE INSPECTION )
36.CHECK PEDAL RESERVE DISTANCE (SEE ON
-VEHICLE INSPECTION )
37.INSTALL COMBINATION METER ASSY (SEE OVERHAUL
)
38.INSTALL INSTRUMENT CLUSTER FINISH PANEL (SEE REPLACEMENT
)
39.INSTALL INSTRUMENT PANEL UNDER COVER SUB-ASSY NO.2 (SEE REPLACEMENT
)
40.INSTALL INSTRUMENT PANEL AIR BAG ASSY LOWER NO.1 (SEE REPLACEMENT
)
41.INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSY NO.1 (SEE REPLACEMENT
)
42.INSTALL OUTER MIRROR SWITCH ASSY
43.INSTALL COIN BOX ASSY
44.INSTALL INSTRUMENT PANEL UNDER COVER SUB-ASSY NO.1 (SEE REPLACEMENT
)
45.INSTALL INSTRUMENT CLUSTER FINISH PANEL CENTER LOWER
46.INSTALL INSTRUMENT CLUSTER FINISH PANEL END
47.INSTALL TURN SIGNAL SWITCH ASSY (SEE REPLACEMENT
)
48.INSTALL SPIRAL CABLE SUB-ASSY (SEE REPLACEMENT
)
49.INSTALL STEERING COLUMN COVER (SEE OVERHAUL
)
50.INSTALL STEERING WHEEL ASSY (SEE OVERHAUL
)
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51.INSTALL HORN BUTTON ASSY (SEE OVERHAUL
)
52.INSTALL STEERING WHEEL COVER LOWER NO.2
53.INSTALL SWITCH & VOLUME CASE
54.CONNECT BATTERY NEGATIVE TERMINAL
55.INSPECT SRS WARNING LIGHT (SEE DIAGNOSIS SYSTEM
)
56.PERFORM INITIALIZATION (SEE PRECAUTION
)
OVERHAUL
1.REMOVE ENGINE ROOM SIDE COVER
2.SEPARATE ENGINE ROOM NO.3 R/B
a. Remove the bolt and separate the engine room No.3 R/B.
3.DRAIN BRAKE FLUID
a. Draw out fluid with syringe.
4.REMOVE BRAKE MASTER CYLINDER SUB-ASSY
a. Remove the clamp from the 2 brake tubes.

Fig. 39: Removing Clamp From Brake Tubes
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
b. Using SST, remove the 2 brake tubes from the master cylinder and ABS & TRACTION actuator
assy.
SST 09751-36011

Fig. 40: Removing Brake Tubes From Master Cylinder And ABS & TRACTION Actuator
Assy
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
c. Disconnect the brake fluid level warning switch connector from the brake master cylinder reservoir.
d. Remove the 2 nuts, vacuum check valve bracket and brake master c
ylinder sub-assy.

Fig. 41: Removing Brake Master Cylinder Sub-Assy Nuts
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
5.REMOVE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSY
a. Remove the brake master cylinder reservoir filler cap and master cylinder reservoir strainer.
HINT:
Using 2 fingers, pull up and turn the master cylinder reservoir strainer counterclockwise to remove.
b. Remove the set screw and pull out the reservoir.

Fig. 42: Locating Set Screw
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
6.REMOVE MASTER CYLINDER RESERVOIR GROMMET
7.REMOVE BRAKE MASTER CYLINDER STRAIGHT PIN
a. Push in the piston by hand and remove the master cylinder straight pin by turning over the cylinder
body.
HINT:
Place a shop ra
g to avoid the master cylinder straight pin from getting damaged.

Fig. 43: Removing Master Cylinder Straight Pin
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
8.REMOVE BRAKE MASTER CYLINDER KIT
a. Place the brake master cylinder sub-assy in a vise.
b. Push in the No.1 piston by hand, and remove the snap ring with snap ring pliers.
c. Remove the No.1 piston b
y hand, pulling straight out, not at an angle.