2005 LEXUS ES300 boot

F41559
F41865
Anti Squeal
Shim No.2 Anti Squeal
Shim No.2
Anti Squeal
Shim No.1
Anti Squeal
Shim No.1
Wear Indicator
- BRAKEREAR BRAKE
32-45
2479 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
32. INSTALL PISTON SEAL
(a) Apply the lithium soap base glycol grease to a new piston seal.
(b) Install the piston seal to the disc brake cylinder.
33. INSTALL REAR DISC BRAKE PISTON
(a) Apply the lithium soap base glycol grease to the piston.
(b) Install the piston to the disc brake cylinder.
NOTICE:
Do not screw the piston forcibly into the disc brake cylinder.
34. INSTALL CYLINDER BOOT
(a) Apply the lithium soap base glycol grease to a new cylin-
der boot.
(b) Install the cylinder boot to the disc brake cylinder.
HINT:
Install the boot securely to the grooves of the cylinder and pis-
ton.
(c) Using a screwdriver, install a new set ring.
NOTICE:
Do not damage the cylinder boot.
35. INSTALL REAR DISC BRAKE CYLINDER MOUNTING LH
(a) Install the disc brake cylinder mounting with the 2 bolts.
Torque: 61.8 NVm (630 kgfVcm, 46 ftVlbf)
36. INSTALL REAR DISC BRAKE PAD SUPPORT PLATE
(a) Install the bottom side rear disc brake pad support plate.
37. INSTALL REAR DISC BRAKE PAD SUPPORT PLATE
(a) Install the upper side rear disc brake pad support plate.
38. INSTALL REAR DISC BRAKE ANTI SQUEAL SHIM KIT
(a) 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.
(b) 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.
39. INSTALL DISC BRAKE PAD KIT REAR (PAD ONLY)
(a) Install the 2 disc brake pads with the pad wear indicator facing downward.
NOTICE:
There should be no oil or grease on the friction surface of the pads and the disc.

F41551
F41562
Cylinder Slide Pin
Cylinder Mounting
Lithium soap base glycol grease
F41558Lithium soap base glycol grease
32-46
- BRAKEREAR BRAKE
2480 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
40. INSTALL REAR DISC BRAKE CYLINDER SLIDE PIN
(a) Using a hexagon wrench (8 mm), install the cylinder slide
pin.
Torque: 39.2 NVm (400 kgfVcm, 29 ftVlbf)
41. INSTALL REAR DISC BRAKE BUSH DUST BOOT
(a) Apply the lithium soap base glycol grease to seal surface
of a new bush dust boot.
(b) Install the bush dust boot to the cylinder slide pin.
42. INSTALL REAR DISC BRAKE CYLINDER SLIDE BUSH
(a) Apply the lithium soap base glycol grease to a new cylin-
der slide bush.
(b) Install the cylinder slide bush to the disc brake cylinder.
43. INSTALL DISC BRAKE CYLINDER ASSY REAR LH
(a) Apply the lithium soap base glycol grease to the cylinder slide pin.
(b) Install the disc brake cylinder to the cylinder slide pin.
44. INSTALL REAR DISC BRAKE CYLINDER SLIDE PIN
(a) Apply the lithium soap base glycol grease to the cylinder slide pin.
(b) Install the cylinder slide pin to the disc brake cylinder.
Torque: 34.3 NVm (350 kgfVcm, 25 ftVlbf)
45. CONNECT REAR LH 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 hole of the disc brake cylinder.
46. FILL RESERVOIR WITH BRAKE FLUID
47. BLEED MASTER CYLINDER (SEE PAGE 32-4)
SST 09023-00101
48. BLEED BRAKE LINE (SEE PAGE 32-4)
49. CHECK FLUID LEVEL IN RESERVOIR (SEE PAGE 32-4)
50. CHECK BRAKE FLUID LEAKAGE
51. INSTALL REAR WHEEL
Torque: 103 NVm (1050 kgfVcm, 76 ftVlbf)

F47192
Non-reusable partSupply Parts:
Front Axle Outboard
Joint Boot RH
No.2 Clamp

Front Drive Outboard
Joint Shaft Assy RHFront Axle Outboard Joint
Boot RH Clamp
Front Drive Shaft
Damper RH Clamp
Front Axle Inboard
Joint Boot RH Clamp
Front Drive Shaft
Dust Cover RH Front Drive Shaft
Dust CoverFront Drive Shaft Hole
Snap Ring RH
Front Drive Inboard
Joint Assy RH
Front Drive Inner Shaft Inner
RH Shaft Snap Ring Front Drive
Shaft Bearing
Front Axle Inboard
Joint Boot
Front Axle Inboard
Joint Boot RH No.2 Clamp













Front Drive Shaft
Dust Cover LH Front Drive Inboard
Joint Assy LH








Front Drive Shaft LH
Hole Snap Ring


Front Drive Shaft
Damper RH
Outboard Joint Boot
LH:
Front Drive Inboard
Joint Assy RH




- DRIVE SHAFT / PROPELLER SHAFTDRIVE SHAFT, PROPELLER SHAFT, AXLE (From July,
2003)30-5
2408 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

C92142
SST
HoldTurn
F40142
D27403
C83850
SST
C66549
- DRIVE SHAFT / PROPELLER SHAFTFRONT DRIVE SHAFT (From July, 2003)
30-9
2412 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
6. DISCONNECT TIE ROD ASSY LH
(a) Remove the cotter pin and nut.
(b) Using SST, separate the tie rod end from the steering
knuckle.
SST 09628-6201 1
7. DISCONNECT FRONT SUSPENSION ARM
SUB-ASSY LOWER NO.1 LH
(a) Remove the bolt and 2 nuts, and disconnect the front sus-
pension arm sub-assy lower No.1 LH from the lower ball
joint.
8. DISCONNECT FRONT AXLE ASSY LH
(a) Using a plastic hammer, separate the drive shaft from the
axle hub.
NOTICE:
Be careful not to damage the boot and speed sensor rotor.
9. REMOVE FRONT DRIVE SHAFT ASSY LH
(a) Using SST, remove the front drive shaft assy LH.
SST 09520-01010, 09520-24010 (09520-32040)
NOTICE:

Be careful not to damage the transaxle case oil seal,
inboard joint boot and drive shaft dust cover.

Be careful not to drop the drive shaft assy.
10. REMOVE FRONT DRIVE SHAFT ASSY RH
(a) Using pliers, remove the drive shaft bearing bracket hole
snap ring.
(b) Remove the bolt and front drive shaft assy RH from the
drive shaft bearing bracket.

C92143
SST
C91598
C67412
F07391
30-10
- DRIVE SHAFT / PROPELLER SHAFTFRONT DRIVE SHAFT (From July, 2003)
2413 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
11. FIX FRONT AXLE ASSY LH
SST 09608-16042 (09608-02021, 09608-02041)
NOTICE:
The hub bearing could be damaged if it is subjected to the
vehicle's full weight, such as when moving the vehicle with
the drive shaft removed.
Therefore, if it is absolutely necessary to place the vehicle
weight on the hub bearing, first support it with SST.
12. INSPECT FRONT DRIVE SHAFT ASSY LH
NOTICE:
Move the drive shaft assy keeping it level.
(a) Check that there is no remarkable play in the radial direc-
tion of the outboard joint.
(b) Check that the inboard joint slides smoothly in the thrust
direction.
(c) Check that there is no remarkable play in the radial direc-
tion of the inboard joint.
(d) Check the boots for damage.
13. REMOVE FRONT AXLE INBOARD JOINT BOOT
CLAMP
(a) One touch type
(1) Using a screwdriver, remove the front axle inboard
joint boot LH clamp and front axle inboard joint boot
LH No.2 clamp, as shown in the illustration.
(b) Claw Engagement type
(1) Using pliers, remove the front axle inboard joint
boot LH clamp and front axle inboard joint boot LH
No.2 clamp, as shown in the illustration.
14. DISCONNECT FR AXLE INBOARD JOINT BOOT
(a) Separate the inboard joint boot from the inboard joint assy.

C91600
Matchmarks
C67414F45046
N00194
Matchmarks
C57543
- DRIVE SHAFT / PROPELLER SHAFTFRONT DRIVE SHAFT (From July, 2003)
30-1 1
2414 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
15. REMOVE FRONT DRIVE INBOARD JOINT ASSY LH
(a) Put matchmarks on the inboard joint assy and outboard
joint shaft.
NOTICE:
Do not use a punch for the marks.
(b) Remove the inboard joint assy from the outboard joint
shaft.
(c) Using a snap ring expander, remove the front drive inner
shaft inner RH shaft snap ring.
(d) Put matchmarks on the outboard joint shaft and tripod
joint.
NOTICE:
Do not use a punch for the marks.
(e) Using a brass bar and hammer, remove the tripod joint
from the outboard joint shaft.
NOTICE:
Do not tap the roller.
16. REMOVE FRONT DRIVE SHAFT DAMPER LH
(a) Using a screwdriver, remove the front drive shaft damper LH clamp.
(b) Remove the front drive shaft damper LH.
17. REMOVE FRONT AXLE OUTBOARD JOINT BOOT CLAMP
(a) Using a screwdriver, remove the front axle outboard joint boot LH clamp and front axle outboard joint
boot LH No.2 clamp.
18. REMOVE OUTBOARD JOINT BOOT
(a) Remove the outboard joint boot from the outboard joint shaft.
(b) Remove the old grease from the outboard joint.
19. REMOVE FRONT DRIVE SHAFT LH HOLE SNAP RING
(a) Using a screwdriver, remove the hole snap ring.

W01994
Vinyl Tape
R10425
SST
R10426
F40646
225.4
2.0 mm
(8.87
0.079 in.) 30-14
- DRIVE SHAFT / PROPELLER SHAFTFRONT DRIVE SHAFT (From July, 2003)
2417 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
28. INSTALL FRONT DRIVE SHAFT LH HOLE SNAP RING
(a) Install a new front drive shaft LH hole snap ring.
29. INSTALL OUTBOARD JOINT BOOT
HINT:
Before installing the boots, wrap the spline of the drive shaft
with vinyl tape to prevent the boots from being damaged.
(a) Hold the drive shaft lightly in a soft vise.
(b) Temporarily install a new outboard joint boot with 2 new
clamps to the drive shaft.
(c) Pack the outboard joint shaft and boot with grease.
Grease capacity:
205 - 215 g (7.2 - 7.6 oz.)
30. INSTALL FRONT AXLE OUTBOARD JOINT BOOT
CLAMP
(a) Hold the drive shaft lightly in a soft vise.
(b) Install the 2 outboard joint boot clamps onto the boot.
(c) Place SST onto the outboard joint large boot clamp.
SST 09521-24010
(d) Tighten the SST so that the large clamp is pinched.
NOTICE:
Do not overtighten the SST.
(e) Using SST, adjust the clearance of the large clamp.
SST 09240-00020
Clearance: 0.8 mm (0.032 in.) or less
(f) Employ the same manner to the outboard joint small boot
clamp.
31. INSTALL FRONT DRIVE SHAFT DAMPER LH
(a) Install the drive shaft damper LH to the drive shaft.
(b) Make sure that the damper is on the shaft groove.
(c) Set the distance, as described below.
Distance: 225.4
2.0 mm (8.87
0.079 in.)
(d) Install a new front drive shaft damper LH clamp to the front
drive shaft damper LH.

C67417
C67414F45046
F40222
Matchmarks
C83397
- DRIVE SHAFT / PROPELLER SHAFTFRONT DRIVE SHAFT (From July, 2003)
30-15
2418 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
32. INSTALL FRONT DRIVE INBOARD JOINT ASSY LH
(a) Temporarily install a new inboard joint boot with 2 new
clamps to the drive shaft.
(b) Place the beveled side of the tripod joint axial spline to-
ward the outboard joint shaft.
(c) Align the matchmarks.
(d) Using a brass bar and hammer, tap in the tripod joint to the
outboard joint shaft.
NOTICE:

Do not tap the roller.

Be sure to install the tripod joint assy in the correct
direction.
(e) Using a snap ring expander, install a new shaft snap ring.
(f) Pack the outboard joint shaft and boot with grease.
Grease capacity: 175 to 185 g (6.25 to 6.61 oz.)
(g) Aligning the matchmarks, install the inboard joint assy to
the outboard joint shaft assy.
33. INSTALL FR AXLE INBOARD JOINT BOOT
(a) Install the inboard joint boot to the inboard joint assy.
34. INSTALL FRONT AXLE INBOARD JOINT BOOT
CLAMP
(a) One touch type
(1) Using a screwdriver, install the front axle inboard
joint boot LH clamp and front axle inboard joint boot
LH No.2 clamp, as shown in the illustration.