2005 LEXUS ES300 brake fluid

320DY-06
F40991
Front Brake Tube
Frame No.1
F40992
F40004
- BRAKEBRAKE MASTER CYLINDER SUB-ASSY
32-21
2455 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
BRAKE MASTER CYLINDER SUB-ASSY (From August,
2002)
OVERHAUL
1. REMOVE AIR CLEANER ASSY
2. DRAIN BRAKE FLUID
NOTICE:
Wash off the brake fluied immediately if it comes into contact with a painted surface.
3. REMOVE BRAKE MASTER CYLINDER SUB-ASSY
(a) Disconnect the level warning switch connector.
(b) Using SST, remove the front brake tube frame No.1.
SST 09023-00101
(c) Using SST, disconnect the 4 brake tubes from the master
cylinder.
SST 09023-00101
(d) Remove the 2 nuts, pull out the 2-way and brake master
cylinder sub-assy.
4. REMOVE BRAKE MASTER CYLINDER RESERVOIR FILLER CAP ASSY
(a) Remove the master cylinder reservoir filler cap assy.
5. REMOVE BRAKE MASTER CYLINDER RESERVOIR STRAINER
(a) Remove the master cylinder reservoir strainer.
6. REMOVE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSY
(a) Remove the screw and pull out the master cylinder reservoir sub-assy.
7. REMOVE MASTER CYLINDER RESERVOIR GROMMET
(a) Remove the 2 master cylinder reservoir grommets.
8. REMOVE BRAKE MASTER CYLINDER KIT (W/O VSC)
(a) Place master cylinder in vise.
(b) Remove the O-ring.
(c) Push in the piston and remove the snap ring with snap
ring pliers.

F40006
SST
F40992
F40991
Front Brake Tube
Frame No. 1
- BRAKEBRAKE MASTER CYLINDER SUB-ASSY
32-25
2459 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(e) Using SST, adjust the booster push rod length until the
push rod lightly touches the pin head.
SST 09737-00020
18. INSTALL BRAKE MASTER CYLINDER SUB-ASSY
(a) Install the master cylinder sub-assy and 2-way with the
2 nuts.
Torque: 13 NVm (130 kgfVcm, 9 ftVlbf)
(b) Using SST and connect the 4 front brake tubes to the
master cylinder sub-assy.
Torque: 15 NVm (155 kgfVcm, 11 ftVlbf)
SST 09023-00101
(c) Using SST and install the front brake tube frame No.1 to
the master cylinder.
Torque: 15 NVm (155 kgfVcm, 11 ftVlbf)
SST 09023-00101
(d) Connect the level warnig switch connector.
19. FILL RESERVOIR WITH BRAKE FLUID
20. BLEED MASTER CYLINDER (SEE PAGE 32-4)
SST 09023-00101
21. BLEED BRAKE LINE (SEE PAGE 32-4)
22. INSTALL AIR CLEANER ASSY
23. CHECK FLUID LEVEL IN RESERVOIR (SEE PAGE 32-4)
24. CHECK BRAKE FLUID LEAKAGE

3211X-04
F40995
F40996
BR3753
32-28
- BRAKEBRAKE BOOSTER ASSY
2462 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
REPLACEMENT
1. REMOVE AIR CLEANER ASSY
2. DRAIN BRAKE FLUID
NOTICE:
Wash off the brake fluid immediately if it comes into contact with a painted surface.
3. REMOVE BRAKE MASTER CYLINDER SUB-ASSY (SEE PAGE 32-21)
SST 09023-00101
4. REMOVE VACUUM HOSE ASSY
(a) Remove the bolt and separate the vacuum hose from the
vacuum hose bracket.
(b) Slide the clip and disconnect the vacuum hose from the
brake booster.
5. REMOVE FRONT DOOR SCUFF PLATE LH (SEE PAGE 71-1 1)
6. REMOVE INSTRUMENT PANEL SUB-ASSY UPPER (SEE PAGE 71-1 1)
7. REMOVE INSTRUMENT PANEL INSERT SUB-ASSY LOWER LH (SEE PAGE 71-1 1)
8. REMOVE BRAKE PEDAL RETURN SPRING
9. REMOVE PUSH ROD PIN
(a) Remove the clip and push rod pin.
10. REMOVE BRAKE MASTER CYLINDER PUSH ROD CLEVIS
(a) Loosen the lock nut and remove the push rod clevis.
11. REMOVE FRONT BRAKE TUBE NO.5
(a) Using SST and remove the front brake tube No.5.
SST 09023-00101
12. REMOVE BRAKE BOOSTER ASSY
(a) Remove the 4 nuts.
(b) Pull out the brake booster assy.

BR3753
F40996
F40995
- BRAKEBRAKE BOOSTER ASSY
32-29
2463 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
13. REMOVE BRAKE BOOSTER GASKET
14. INSTALL BRAKE BOOSTER GASKET
(a) Install a new brake booster gasket to the brake booster.
15. INSTALL BRAKE BOOSTER ASSY
(a) Install the brake booster with the 4 nuts.
Torque: 13 NVm (130 kgfVcm, 9 ftVlbf)
16. INSTALL FRONT BRAKE TUBE NO.5
(a) Using SST and install the front brake tube No.5.
Torque: 15 NVm (155 kgfVcm, 11 ftVlbf)
SST 09023-00101
17. INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS
(a) Install the push rod clevis and lock nut.
18. INSTALL PUSH ROD PIN
(a) Install the push rod pin and clip.
HINT:
Apply the lithium soap base glycol grease to the part indicate by arrow (see page 32-27).
19. INSTALL BRAKE PEDAL RETURN SPRING
20. INSTALL INSTRUMENT PANEL INSERT SUB-ASSY LOWER LH (SEE PAGE 71-1 1)
21. INSTALL INSTRUMENT PANEL SUB-ASSY UPPER (SEE PAGE 71-1 1)
22. INSTALL FRONT DOOR SCUFF PLATE LH (SEE PAGE 71-1 1)
23. INSTALL VACUUM HOSE ASSY
(a) Install the vacuum hose and vacuum hose bracket to the
body with a bolt.
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
(b) Connect the vacuum hose to the brake booster with the
clip.
24. INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD (SEE PAGE 32-21)
SST 09737-00013, 09737-00020
25. INSTALL BRAKE MASTER CYLINDER SUB-ASSY (SEE PAGE 32-21)
SST 09023-00101
26. FILL RESERVOIR WITH BRAKE FLUID

32-30
- BRAKEBRAKE BOOSTER ASSY
2464 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
27. BLEED MASTER CYLINDER (SEE PAGE 32-4)
SST 09023-00101
28. BLEED BRAKE LINE (SEE PAGE 32-4)
29. INSTALL AIR CLEANER ASSY
30. CHECK FLUID LEVEL IN RESERVOIR (SEE PAGE 32-4)
31. CHECK BRAKE FLUID LEAKAGE
32. CHECK AND ADJUST BRAKE PEDAL HEIGHT (SEE PAGE 32-8 or 32-12)

320E6-04
F41534
F41535
F41536
- BRAKEFRONT BRAKE
32-33
2467 Author
: Date
:
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.

F41539
F41560
- BRAKEFRONT BRAKE
32-35
2469 Author
: Date
:
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.

F41866
Anti Squeal
Shim
Wear Indicator
- BRAKEFRONT BRAKE
32-39
2473 Author
: Date
:
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)