1992 Lexus ES300 brake

SECTION 6 – 3
173
SERVICE PROCEDURES AND
SPECIFICATIONS
Chassis
Specifications174 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking clutch pedal freeplay176 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking brake and clutch fluids176 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking brake pedal freeplay177 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking brake pedal clearance178 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking parking brake adjustment178 . . . . . . . . . . . . . . . . . . . . . . . .
Checking the brake booster179 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking power steering fluid179 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking steering wheel freeplay180 . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking automatic transmission fluid181 . . . . . . . . . . . . . . . . . . . . . .
Checking lire pressure182 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotating tires183 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking and replacing tires184 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing snow tires and chains186 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing wheels187 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Aluminum wheel precautions187 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHASSIS
174
SPECIFICATIONS
− MANUAL TRANSAXLE
Oil capacity
Oil type
Recommended oil viscosity
4.2 L (4.4 qt., 3.7 Imp.qt.)
Multipurpose gear oil API GL-5
SAE 75 W − 90
− AUTOMATIC TRANSMISSION
Fluid capacity
Dry fill
Drain and refill
Fluid type
6.5 L (6.8 qt., 5.7 Imp.qt.)
3.1 L (3.3 qt., 2.7 Imp.qt.)
Automatic transmission fluid DEXRON
®-II
− DIFFERENTIAL (Automatic transmission)
Fluid capacity
Fluid type:
0.8 L (0.8 qt., 0.7 Imp.qt.)
Automatic transmission fluid DEXRON®-II
− CLUTCHES
Pedal freeplay
Fluid type
5 − 15 mm (0.2 − 0.6 in.)
FMVSS No. 116 DOT 3 or SAE J1703
− BRAKES
Minimum pedal clearance when depressed,
Pedal freeplay
Pad wear limit
Parking brake lining wear limit
Parking brake adjustment
Fluid type
70 mm (2.8 in.) Min.
1 − 6 mm (0.04 − 0.24 in.)
1.0 mm (0.04 in.)
1.0 mm (0.04 in.)
5 − 8 clicks
SAE J1703 or FMVSS No. 116 DOT 3

CHASSIS
176
CHECKING CLUTCH PEDAL
FREEPLAY
5 - 15 mm
(0.2 - 0.6 in.)
Press down lightly on the clutch pedal and measure the
distance it moves freely before the clutch resistance is
felt. The freeplay should be within the above limits.
If the freeplay is more or less, have your Lexus dealer inspect
the clutch.
CHECKING BRAKE AND
CLUTCH FLUIDS
Maximum level line
Brake fluid reservoir
Clutch fluid reservoir
Maximum level line
To check the fluid levels, simply look at the see-through
reservoirs. The brake and clutch fluid levels should be
between the “MAX” and “MIN” lines on the tanks.

CHASSIS
177 It is normal for the brake fluid level to go down slightly as the
brake pads wear. So be sure to keep the reservoir filled.
If any reservoir needs frequent refilling, it may indicate a
serious mechanical problem.
If the level is low, add FMVSS No. 116 DOT 3 or SAE J1703
brake fluid to the brake or clutch reservoir.
Remove and replace the reservoir cover by hand. Add brake
fluid up to the line.
Use only newly opened brake fluid. Once opened, brake fluid
absorbs moisture from the air, and excess moisture can cause
a dangerous loss of braking.
CAUTION:
Take care when filling the reservoirs because brake fluid
can harm your eyes and damage painted surfaces. If fluid
gets in your eyes, flush your eyes with clean water.
NOTICE:
If you spill some of the fluid, be sure to wash it off with
water to prevent it from damaging the parts or
paintwork.
CHECKING BRAKE PEDAL
FREEPLAY
1 - 6 mm
(0.04 - 0.24 in.)
With the engine stopped, first reduce the vacuum in the
booster by depressing the brake pedal several times.
Then lightly and slowly press down on the pedal with your
fingers and measure the distance it moves before slight
resistance is felt.
If the freeplay is more or less than specification, have your
Lexus dealer adjust the brakes.

CHASSIS
178
CHECKING BRAKE PEDAL
CLEARANCE
70 mm (2.8 in.) Min.
With the engine running, have someone press the brake
pedal several times and then press hard (approximately
490 N [50 kgf, 110 lb.]) on it. The distance from the asphalt
sheet to the top surface of the pedal should not be less
than specified.
If the clearance is less, your Lexus dealer should adjust the
brakes.
CHECKING PARKING BRAKE
ADJUSTMENT
5 - 8 clicks
Count the number of clicks as you slowly pull up the
parking brake as far as it will go (approximately 196 N [20
kgf, 44 lb.]). The adjustment is correct if you hear 5 to 8
clicks.
If you count more or less clicks, have the parking brake
adjusted by your Lexus dealer.

CHASSIS
179
CHECKING THE BRAKE
BOOSTER
Sit in the driver’s seat and follow the instructions given
below. If your brakes do not operate as described, have
them checked at your Lexus dealer.
1. With the engine stopped, depress the brake pedal several
times: the travel distance should not change.
2. With the brake fully depressed, start the engine: the pedal
should move down a little when the engine starts.
3. Depress the brake, stop the engine, and hold the pedal in
for about 30 seconds: the pedal should sink slightly when the
engine stops. Afterward, the pedal should neither sink nor rise.
4. Restart the engine, run it for about a minute and turn it off.
Then firmly depress the brake several times: the pedal travel
should decrease with each application.
CHECKING POWER STEERING
FLUID
Power steering
fluid reservoir
Check the fluid level through the reservoir. If necessary,
add DEXRON®-II automatic transmission fluid.
If the vehicle has been driven around 80 km/h (50 mph) for 20
minutes (a little more in frigid temperatures), the fluid is hot
(60
C − 80
C or 140
F − 175
F). You may also check the level
when the fluid is cold (about room temperature, 10
C − 30
C
or 50
F − 85
F) if the engine has not been run for about five
hours.

CHASSIS
181
CHECKING AUTOMATIC
TRANSMISSION FLUID
1. Check the fluid level only when the transmission is at
normal operating temperature. With the vehicle level, first
set the parking brake and then start the engine. While the
engine is idling, depress the brake pedal and shift the
selector lever into each range from “P” to “L” and return
to “P”.
If the vehicle has been driven over 16 km or 10 miles (24 km
or 15 miles in frigid temperatures) and the fluid temperature is
70
C − 80
C (160
F − 175
F), the transmission is at normal
operating temperature.
You may check the level when the transmission is cold. If the
vehicle has not been driven for over five hours and the fluid is
about room temperature 20
C − 30
C (70
F − 85
F), the
transmission is cold.
However, checking a cold transmission is to be used for your
reference only and the transmission must be checked again for
correct level at normal operating temperature.
If the vehicle has just been driven for a long time at high speed,
in city traffic in hot weather, or the vehicle has been pulling a
trailer, an accurate fluid level cannot be obtained. Check the
level after the fluid has cooled down (about 30 minutes.)
2. With the engine still idling, check the fluid level and
condition on the dipstick. If necessary, add DEXRON®-II
automatic transmission fluid.
a. Release the clips, pull the dipstick out and wipe it clean.
b. Reinsert the dipstick−push it in as far as it will go.

CHASSIS
187
REPLACING WHEELS
When to replace your wheels
If you have wheel damage such as bends, cracks or heavy
corrosion, the wheel should be replaced.
If you fail to replace damaged wheels, a tire may slip off a wheel
or they may cause loss of handling control.
Replacement with used wheels is not recommended as they
may have been subjected to rough treatment or high mileage
and could fail without warning. Also, bent wheels which have
been straightened may have hidden structural damage and
therefore should not be used. Never use an inner tube in a
leaking wheel which is designed for a tubeless tire.
Wheel selection
When replacing wheels, care should be taken to ensure
that they are equivalent to those removed in load capacity,
diameter, rim width, and offset.
Correct replacement wheels are available at your Lexus
dealer.
A wheel of a different size or type may adversely affect
handling, wheel and bearing life, brake cooling,
speedometer/odometer calibration, stopping ability, headlight
aim, bumper height, vehicle ground clearance, and lire or snow
chain clearance to the body and chassis.
ALUMINUM WHEEL PRECAUTIONS
After driving your vehicle the first 1600 km (1000 miles),
check that the wheel nuts are tight.
If you have rotated, repaired, or changed your tires, check
that the wheel nuts are still tight after driving 1600 km (1000
miles).
When using tire chains, be careful not to damage the
aluminum wheels.
Use only the Lexus wheel nuts and wrench designed for
your aluminum wheels.
When balancing your wheels, use only Lexus balance
weights or equivalent and a plastic or rubber hammer.
As with any wheel, periodically check your aluminum
wheels for damage. If damaged, replace immediately.