Disc Brakes: Removal & Installation Lexus LS III

Removal

1. Raise and support vehicle. Remove wheels. Check brake pads for minimum thickness. See «DISC BRAKE SPECIFICATIONS»(ref-127897-S15914230852001103000000). Hold bottom sliding pin, and remove installation bolt. Without disconnecting flexhose, lift bottom of brake caliper up, and wire aside. (Scheme 1)- (Scheme 4). On RX300, remove bolt and flexhose from shock absorber.
2. Remove 2 anti-squeal springs, 2 brake pads, 4 anti-squeal shims, 4 pad support plates and pad wear indicator plate. On LS430, disconnect pad wire wear indicator from the inside pad. On all models, check rotors for minimum thickness and lateral runout.

Installation

1. Install NEW wear indicators on brake pads. Apply disc brake grease to both sides of inner anti-squeal shim. Install 2 anti-squeal shims on each pad. Install 2 anti-squeal springs. Install 2 pads with wear indicator plates facing down. Install brake pads. On LS430, connect pad wire wear indicator to inside pad using a NEW clip. On RX300, install flexhose and bolt to shock absorber.
2. Remove 25 percent of brake fluid from reservoir. Compress pistons into caliper bore. Install caliper over brake pad assembly onto slide pins. Hold sliding pin and tighten caliper installation bolts to specification. See «TORQUE SPECIFICATIONS»(ref-127897-S31888588902001103000000) . Check brake reservoir fluid level and ensure correct brake operation.

Scheme 1

Scheme 2

Scheme 3

Scheme 4

1. Raise and support vehicle. Remove front wheels. Disconnect flexhose from caliper and cap hose. Remove union bolt and 2 gaskets from caliper. (Scheme 1)- (Scheme 4).
2. Remove 2 caliper installation bolts. Remove caliper from torque plate. Remove pads, anti-squeal shims and support plates.

To install, reverse removal procedure. Tighten installation bolts to specification. See TORQUE SPECIFICATIONS .

Raise and support vehicle. Remove wheel. Remove caliper attaching bolts. Remove front brake caliper and pads. See FRONT BRAKE PADS . Check rotor thickness and runout. Before measuring rotor runout, confirm hub bearing play is within specification. See DISC BRAKE SPECIFICATIONS . Remove rotor.

Place rotor on hub. Install caliper attaching bolts, and tighten to specification. See TORQUE SPECIFICATIONS . Remove 25 percent of brake fluid from brake reservoir. Compress caliper pistons. Install caliper over brake pad assembly (onto slide pins). Hold slide pins and tighten installation bolts to specification. See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure.

1. Raise and support vehicle. Remove rear wheels. Check brake pad thickness. See «DISC BRAKE SPECIFICATIONS»(ref-127897-S15914230852001103000000).
2. On ES300 and RX300 2WD, remove flexhose bracket from shock absorber. On all models, hold bottom sliding pin and remove installation bolt. Without disconnecting flexhose, lift bottom of brake caliper up and suspend it using wire.
3. Remove 2 brake pads, 4 anti-squeal shims and 4 pad support plates. (Scheme 5), (Scheme 6) or (Scheme 7). Check rotors for minimum thickness and lateral runout.

1. Remove 25 percent of brake fluid from reservoir. Compress piston in caliper bore. Apply disc brake grease to both sides of inner anti-squeal shim. Install 2 anti-squeal shims onto each pad. Install pad support plates onto brake pads with pad wear indicators facing upward.
2. Install caliper over slide pin(s). Hold sliding pin and tighten installation bolts. See «TORQUE SPECIFICATIONS»(ref-127897-S31888588902001103000000) . To complete installation, reverse removal procedure. Check brake reservoir fluid level and ensure correct brake operation.

Scheme 5

Scheme 6

Scheme 7

1. Raise and support vehicle. Remove rear wheels. Remove union bolt and 2 gaskets. Disconnect flexhose from caliper.
2. To remove caliper, hold sliding pin and remove 2 installation bolts. Remove caliper from torque plate. Remove anti-squeal springs, brake pads with anti-squeal shims and support plates.

To install, reverse removal procedure. Bleed brake system. See BLEEDING PROCEDURES . Tighten bolts to specification. See TORQUE SPECIFICATIONS .

Raise and support vehicle. Remove rear wheels. Remove caliper attaching bolts. Remove rear caliper and pads. See REAR BRAKE PADS . Check rotor minimum thickness and lateral runout. See DISC BRAKE SPECIFICATIONS . Remove rotor.

1. Place rotor on rear hub. Install caliper torque plate, and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-127897-S31888588902001103000000) . Remove 25 percent of brake fluid from reservoir. Compress caliper pistons.
2. Install caliper over brake pad assembly (onto sliding pins). Hold sliding pins and tighten bolts. See «TORQUE SPECIFICATIONS»(ref-127897-S31888588902001103000000) . To complete installation, reverse removal procedure.

1. Remove air cleaner cover with air cleaner housing (if equipped). On RX300, disconnect reservoir assembly from bracket. On all models, disconnect fluid level warning switch connector. Using syringe, remove brake fluid from reservoir.
2. Disconnect brakelines from master cylinder. Remove master cylinder and gasket.

To install, reverse removal procedure. Tighten mounting nuts and brakelines to specification. See TORQUE SPECIFICATIONS . Bleed brake and TRAC systems (if equipped). See BLEEDING BRAKE SYSTEM .

Removal (ES300 & RX300)

1. Remove air cleaner cover with air cleaner hose. Remove master cylinder. See «MASTER CYLINDER»(ref-127897-S18110191342001103000000) .
2. Disconnect vacuum hose from power brake unit. Disconnect 3 brake lines from clamp. Remove pedal return spring. Remove clip and clevis pin. Remove power brake booster, gasket and clevis.

Installation (ES300 & RX300)

1. Install brake booster and NEW gasket. Install and tighten booster bolts to 9 ft. lbs (13 N.m). Install clevis, and tighten lock nut to 19 ft. lbs (25 N.m). Install clevis pin into clevis and brake pedal. Install clip to clevis pin. Install pedal return spring.
2. Ensure power brake unit push rod length is correct. See «POWER BRAKE UNIT PUSH ROD»(ref-127897-S18796326932001103000000) under ADJUSTMENTS. Install master cylinder. See «MASTER CYLINDER»(ref-127897-S18110191342001103000000) under REMOVAL & INSTALLATION.
3. Connect vacuum hose to brake booster. Connect 3 brake lines to clamp. Fill brake reservoir with brake fluid and bleed brake system. See «BLEEDING BRAKE SYSTEM»(ref-127897-S12727542812001103000000) . Check for fluid leakage. Ensure brake pedal height is correct. See «BRAKE PEDAL HEIGHT & FREE PLAY»(ref-127897-S38329378912001103000000) under ADJUSTMENTS.

Removal (GS300 & GS430)

Note. Before starting procedure, turn ignition OFF. Depress brake pedal more than 40 times to deplete booster pressure. DO NOT turn ignition on until booster is reinstalled.

1. Using syringe, draw fluid from hydraulic brake booster. Remove No. 1 under cover, end pad and No. 1 safety pad. Remove No. 7 heater-to-register duct.
2. Disconnect 4 brake lines from booster. Disconnect left front wheel brake line from flexhose. Remove 2 brake line clamps.
3. Disconnect level warning switch connector. Disconnect 4 electrical connectors. Remove pedal return spring, clip and clevis pin. Remove locknut and remove clevis. Remove hydraulic brake booster assembly.

Installation (GS300 & GS430)

To install, reverse removal procedure. Fill brake reservoir with brake fluid and bleed brake system. See BLEEDING BRAKE SYSTEM . Check for fluid leakage.

Removal (IS300)

1. Remove master cylinder. See «MASTER CYLINDER»(ref-127897-S18110191342001103000000) . Disconnect vacuum hose. Disconnect front-left brake line from flexible hose. Separate grommet from body through brake line. Disconnect front-left brake line from clamp.
2. Remove 3 bolts and disconnect 3 clamps. Remove lower finish panel. Remove return spring, clip and clevis pin. Remove clevis and nuts.
3. Move brake line down and back to allow removal of booster assembly. Remove booster and gasket.

Installation (IS300)

1. Install brake booster and NEW gasket. Install and tighten booster bolts to 9 ft. lbs (13 N.m). Install clevis pin into clevis and brake pedal. Install clip to clevis pin. Install pedal return spring. Install vacuum hose. Install 3 clamps with bolts and tighten to 43 INCH lbs. (4.9 N.m).
2. Connect front left brake line to clamp. Connect brake line to flexible hose. Tighten to 11 ft. lbs. (15 N.m). Attach grommet to body through brake line.
3. Ensure power brake unit push rod length is correct. See «POWER BRAKE UNIT PUSH ROD»(ref-127897-S18796326932001103000000) under ADJUSTMENTS. Install master cylinder. See «MASTER CYLINDER»(ref-127897-S18110191342001103000000) under REMOVAL & INSTALLATION.
4. Fill brake reservoir with brake fluid and bleed brake system. See «BLEEDING BRAKE SYSTEM»(ref-127897-S12727542812001103000000) . Check for fluid leakage. Ensure brake pedal height is correct. See «BRAKE PEDAL HEIGHT & FREE PLAY»(ref-127897-S38329378912001103000000) under ADJUSTMENTS. Install lower finish panel.

Removal (LS430)

1. Remove master cylinder. See «MASTER CYLINDER»(ref-127897-S18110191342001103000000) under REMOVAL & INSTALLATION.
2. Remove No. 1 under cover and No. 1 safety pad. Remove clip and return spring.
3. Remove clevis pin. Remove vacuum hose from brake booster. Remove booster installation nuts and clevis. Pull out brake booster and gasket.

Installation (LS430)

1. Install brake booster and NEW gasket. Install and tighten booster installation nuts to 9 ft. lbs. (13 N.m). Install clevis pin into clevis and brake pedal. Install clip to clevis pin. Install pedal return spring.
2. Ensure power brake unit push rod length is correct. See «POWER BRAKE UNIT PUSH ROD»(ref-127897-S18796326932001103000000) under ADJUSTMENTS. Install master cylinder. See «MASTER CYLINDER»(ref-127897-S18110191342001103000000) under REMOVAL & INSTALLATION.
3. Fill brake reservoir with brake fluid and bleed brake system. See «BLEEDING BRAKE SYSTEM»(ref-127897-S12727542812001103000000) . Check for fluid leakage. Ensure brake pedal height is correct. See «BRAKE PEDAL HEIGHT & FREE PLAY»(ref-127897-S38329378912001103000000) under ADJUSTMENTS.

1. Remove rear wheels. Remove 2 mounting bolts and remove disc brake assembly. Support disc brake assembly so that flexhose is not stretched. Using paint, place match marks on disc and hub for installation reference. Remove disc brake rotor. If disc brake rotor cannot be removed, remove adjustor hole plug and loosen parking brake shoe adjustment.
2. Remove 2 parking brake shoe return springs. (Scheme 8) Remove shoe strut with spring. Remove front shoe hold-down cup, spring, backing plate and pin. Remove front and rear shoes, adjuster and tension springs. Remove rear shoe hold-down cup, spring, pin and backing plate. Remove cable from parking brake lever.

Scheme 8

On ES300, IS300 and RX300 models, install parking brake shoe lever with new "C" clip. On all models, to complete installation, reverse removal procedure.

PARKING BRAKE SPECIFICATIONS