2005 LEXUS ES300 Repair Manual

3305I-02
F41009
F41010
33-6
- PARKING BRAKEPARKING BRAKE CONTROL PEDAL ASSY
2502 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
PARKING BRAKE CONTROL PEDAL ASSY
OVERHAUL
HINT:
COMPONENTS: See page 71-8 and 33-3
1. REMOVE INSTRUMENT CLUSTER FINISH PANEL SUB-ASSY(See page 71-1 1)
2. REMOVE COMBINATION METER ASSY(See page 71-1 1)
3. REMOVE FRONT DOOR SCUFF PLATE LH(See page 71-1 1)
4. REMOVE INSTRUMENT PANEL SUB-ASSY UPPER(See page 71-1 1)
5. REMOVE INSTRUMENT PANEL INSERT SUB-ASSY LOWER LH(See page 71-1 1)
6. REMOVE PARKING BRAKE CONTROL PEDAL ASSY
(a) Disconnect the parking brake switch connector.
(b) Remove the 2 bolts, nut and parking brake control pedal
assy.
7. DISCONNECT PARKING BRAKE CABLE ASSY NO.1
(a) Remove the lock nut, adjusting nut and clip, then discon-
nect the parking brake cable assy No.1 from the parking
brake control pedal assy.
8. REMOVE PARKING BRAKE SWITCH ASSY
(a) Remove the screw and parking brake switch assy.
9. REMOVE TENSION SPRING
10. REMOVE RETURN SPRING DAMPER
11. REMOVE PARKING PEDAL PAD

F41010
F41009
- PARKING BRAKEPARKING BRAKE CONTROL PEDAL ASSY
33-7
2503 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
12. INSTALL PARKING PEDAL PAD
13. INSTALL RETURN SPRING DAMPER
14. INSTALL TENSION SPRING
15. INSTALL PARKING BRAKE SWITCH ASSY
(a) Install the parking brake switch assy with the screw.
16. CONNECT PARKING BRAKE CABLE ASSY NO.1
(a) Connect the parking brake cable assy No.1 with the clip,
adjusting nut and lock nut.
17. INSTALL PARKING BRAKE CONTROL PEDAL ASSY
(a) Install the parking brake control pedal assy with the 2
bolts and nut.
Torque: 39 NVm (398 kgfVcm, 29 ftVlbf)
(b) Connect the parking brake switch connector.
18. INSTALL INSTRUMENT PANEL INSERT SUB-ASSY LOWER LH
19. INSTALL INSTRUMENT PANEL SUB-ASSY UPPER
20. INSTALL FRONT DOOR SCUFF PLATE LH
21. INSTALL COMBINATION METER ASSY
22. INSTALL INSTRUMENT CLUSTER FINISH PANEL SUB-ASSY
23. INSPECT AND ADJUST PARKING BRAKE PEDAL TRAVEL(See page 33-2)

3305J-02
C90470
Turn
Buckle
F41010
33-8
- PARKING BRAKEPARKING BRAKE CABLE ASSY NO.1
2504 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
PARKING BRAKE CABLE ASSY NO.1
REPLACEMENT
HINT:
COMPONENTS: See page 71-8 and 33-3
1. REMOVE FRONT DOOR SCUFF PLATE RH
2. REMOVE FRONT DOOR SCUFF PLATE LH
3. REMOVE INSTRUMENT PANEL SUB-ASSY UPPER(See page 71-1 1)
4. REMOVE INSTRUMENT PANEL INSERT SUB-ASSY LOWER LH(See page 71-1 1)
5. REMOVE INSTRUMENT PANEL UNDER COVER SUB-ASSY NO.1(See page 71-1 1)
6. REMOVE INSTRUMENT PANEL SUB-ASSY LOWER(See page 71-1 1)
7. REMOVE CONSOLE PANEL UPPER REAR(See page 71-1 1)
8. REMOVE CONSOLE BOX CARPET
9. REMOVE RR CONSOLE BOX(See page 71-1 1)
10. REMOVE INSTRUMENT PANEL FINISH PANEL END RH
11. REMOVE INSTRUMENT PANEL FINISH PANEL END LH(See page 71-1 1)
12. REMOVE AIR DUCT REAR NO.1
13. REMOVE AIR DUCT REAR NO.2
14. REMOVE CONSOLE BOX DUCT NO.1
15. REMOVE YAWRATE SENSOR (W/ VSC)(See page 32-59)
16. REMOVE PARKING BRAKE CABLE ASSY NO.1
(a) Loosen the turn buckle, disconnect the parking brake
cable assy No.1 from the parking brake cable assy No.4.
(b) Remove the 2 bolts and console box mounting bracket
No.2.
(c) Remove the lock nut, adjusting nut and clip, then discon-
nect the parking brake cable assy No.1 from the parking
brake control pedal assy.

F41687
F41687
F41010
C90470
Turn
Buckle
- PARKING BRAKEPARKING BRAKE CABLE ASSY NO.1
33-9
2505 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(d) Remove the 2 nuts, 2 bolts, clip and parking brake cable
assy No.1.
17. INSTALL PARKING BRAKE CABLE ASSY NO.1
(a) Install the parking brake cable assy No.1 with the 2 nuts,
2 bolts and clip.
(b) Install the parking brake cable assy No.1 with the clip, ad-
justing nut and lock nut to the parking brake control pedal
assy.
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
(c) Install the console box mounting bracket No.2 with the 2
bolts.
Torque: 12.5 NVm (128 kgfVcm, 9 ftVlbf)
(d) Tighten the turn buckle, connect the parking brake cable
assy No.1 to the parking brake cable assy No.4.
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)

33-10
- PARKING BRAKEPARKING BRAKE CABLE ASSY NO.1
2506 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
18. INSTALL YAWRATE SENSOR (W/ VSC)(See page 32-59)
19. INSTALL CONSOLE BOX DUCT NO.1
20. INSTALL AIR DUCT REAR NO.2
21. INSTALL AIR DUCT REAR NO.1
22. INSTALL INSTRUMENT PANEL FINISH PANEL END LH
23. INSTALL INSTRUMENT PANEL FINISH PANEL END RH
24. INSTALL RR CONSOLE BOX
25. INSTALL CONSOLE BOX CARPET
26. INSTALL CONSOLE PANEL UPPER REAR
27. INSTALL INSTRUMENT PANEL SUB-ASSY LOWER
28. INSTALL INSTRUMENT PANEL UNDER COVER SUB-ASSY NO.1
29. INSTALL INSTRUMENT PANEL INSERT SUB-ASSY LOWER LH
30. INSTALL INSTRUMENT PANEL SUB-ASSY UPPER
31. INSTALL FRONT DOOR SCUFF PLATE LH
32. INSTALL FRONT DOOR SCUFF PLATE RH
33. INSPECT AND ADJUST PARKING BRAKE PEDAL TRAVEL(See page 33-2)
34. CHECK VSC SENSOR SIGNAL (W/ VSC)(See page 05-471)

3305K-02
C90471
C90462F41690
- PARKING BRAKEPARKING BRAKE CABLE ASSY NO.3
33-1 1
2507 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
PARKING BRAKE CABLE ASSY NO.3
REPLACEMENT
HINT:

COMPONENTS: See page 33-3

For parking brake cable No.2, employ the same procedure to the RH side.
1. REMOVE REAR WHEEL
2. REMOVE REAR DISC BRAKE CALIPER ASSY LH
(a) Remove the 2 bolts and separate the rear disc brake caliper assy LH.
HINT:
Do not the flexible hose from the brake caliper assy LH.
3. REMOVE REAR DISC(See page 33-16)
4. REMOVE PARKING BRAKE SHOE RETURN TENSION SPRING(See page 33-16)
5. REMOVE PARKING BRAKE SHOE STRUT COMPRESSION SPRING(See page 33-16)
6. REMOVE PARKING BRAKE SHOE STRUT LH(See page 33-16)
7. REMOVE PARKING BRAKE SHOE(See page 33-16)
8. REMOVE PARKING BRAKE CABLE HEAT INSULATOR
(a) Remove the 3 nuts and parking brake heat insulator.
9. REMOVE PARKING BRAKE CABLE ASSY NO.3
(a) Remove the 2 bolts and disconnect the parking brake
cable assy No.3 from the backing plate.
(b) Remove the 2 nuts, bolt and parking brake cable assy
No.3.

C90462F41690
C90471
33-12
- PARKING BRAKEPARKING BRAKE CABLE ASSY NO.3
2508 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(c) Disconnect the parking brake cable assy No.3 from the
parking brake equalizer.
10. INSTALL PARKING BRAKE CABLE ASSY NO.3
(a) Connect the parking brake cable assy No.3 to the parking
brake equalizer.
(b) Install the parking brake cable assy No.3 with the 2 nuts
and bolt.
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
(c) Install the parking brake cable assy No.3 with the 2 bolts
to the backing plate.
Torque: 7.8 NVm (80 kgfVcm, 69 in.Vlbf)
11. INSTALL PARKING BRAKE CABLE HEAT INSULATOR
(a) Install the parking brake heat insulator with the 3 nuts.
Torque: 5.4 NVm (55 kgfVcm, 48 kgfVcm)
12. APPLICATION HIGH TEMPERATURE GREASE(See page 33-16)
13. INSTALL PARKING BRAKE SHOE(See page 33-16)

- PARKING BRAKEPARKING BRAKE CABLE ASSY NO.3
33-13
2509 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
14. INSTALL PARKING BRAKE SHOE STRUT LH(See page 33-16)
15. INSTALL PARKING BRAKE SHOE STRUT COMPRESSION SPRING(See page 33-16)
16. INSTALL PARKING BRAKE SHOE RETURN TENSION SPRING(See page 33-16)
17. CHECK PARKING BRAKE INSTALLATION(See page 33-16)
18. INSTALL REAR DISC(See page 33-16)
19. ADJUST PARKING BRAKE SHOE CLEARANCE(See page 33-16)
20. INSTALL REAR DISC BRAKE CALIPER ASSY LH
(a) Install the rear disc brake caliper with the 2 bolts.
Torque: 47 NVm (480 kgfVcm, 35 ftVlbf)
21. INSTALL REAR WHEEL
Torque: 103 NVm (1,050 kgfVcm, 76 ftVlbf)
22. INSPECT AND ADJUST PARKING BRAKE PEDAL TRAVEL(See page 33-2)