2005 LEXUS ES300 boot

320E5-02
F41863
Front Disc
Front Disc Brake
Bleeder Plug
Front Flexible Hose Union Bolt

Gasket
Front Disc Brake
Bleeder Plug Cap
Disc Brake
Cylinder Assy LH

Set Ring

Cylinder BootFront Disc
Brake Piston

Piston Seal
Front Disc Brake
Cylinder Slide Pin
Front Disc Brake
Cylinder Slide Bush
Front Disc Brake
Bush Dust Boot
Front Disc Brake
Bush Dust Boot
Front Disc Brake
Cylinder Slide Pin
Front Disc Brake
Cylinder Mounting LH
Front Disc Brake
Pad Support Plate
Disc brake grease Lithium soap base glycol grease
Non-reusable part


NVm (kgfVcm, ftVlbf)
: Specified torque Single Piston Type:






Anti Squeal
Shim No.1
Disc Brake
Pad Kit Front Anti Squeal
Shim No.1
Anti Squeal
Shim No.2
Anti Squeal
Shim No.2
Wear Indicator
8.3 (85, 74 in.Vlbf)
29.4 (300, 22)34.3 (350, 25)
34.3 (350, 25)
106.9 (1,090, 79)
106.9 (1,090, 79)
- BRAKEFRONT BRAKE
32-31
2465 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
FRONT BRAKE
COMPONENTS

F41533Disc brake grease Lithium soap base glycol grease
Non-reusable part


NVm (kgfVcm, ftVlbf)
: Specified torque Front Disc Brake
Bleeder Plug
Front Flexible Hose Union Bolt

Gasket
Front Disc Brake
Bleeder Plug Cap
Front Disc Brake
Cylinder Slide Pin
Front Disc Brake
Cylinder Slide Bush
Front Disc Brake
Bush Dust Boot
Front Disc Brake
Bush Dust Boot
Front Disc Brake
Cylinder Slide Pin
Front Disc Brake
Cylinder Mounting LH
Front Disc Brake
Pad Support Plate
Front Disc
Anti Squeal
Shim
Disc Brake
Pad Kit Front
Twin Piston Type:

Set Ring

Cylinder Boot Front Disc
Brake Piston

Piston Seal




Disc Brake
Cylinder Assy LH
Anti Squeal
ShimWear Indicator
106.9 (1,090, 79)
106.9 (1,090, 79)
34.3 (350, 25)
8.3 (85, 74 in.Vlbf)
29.4 (300, 22)
34.3 (350, 25)
32-32
- BRAKEFRONT BRAKE
2466 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

F41537
F41561
C68791
F41563
F41564
32-34
- BRAKEFRONT BRAKE
2468 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
10. REMOVE FRONT DISC BRAKE CYLINDER SLIDE
BUSH
(a) Remove the cylinder slide bush from the cylinder slide
pin.
11. REMOVE FRONT DISC BRAKE CYLINDER
MOUNTING LH
(a) Remove the 2 bolts and disc brake cylinder mounting.
12. REMOVE FRONT DISC BRAKE BUSH DUST BOOT
(a) Place front disc brake cylinder mounting in vise.
(b) Using a screwdriver and hammer, remove the 2 bush dust
boots from the disc brake cylinder mounting.
13. REMOVE CYLINDER BOOT
(a) Using a screwdriver, remove the set ring and cylinder boot
from the disc brake cylinder (Single piston Type).
(b) Using a screwdriver, remove the 2 set rings and 2 cylinder
boots from the disc brake cylinder (Twin piston Type).

F41544
F41565
- BRAKEFRONT BRAKE
32-37
2471 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
25. INSPECT DISC RUNOUT
(a) Temporarily install the disc with hub nuts.
Torque: 103 NVm (1,050 kgfVcm, 76 ftVlbf)
(b) Using a dial indicator, measure the disc runout 10 mm
(0.39 in.) away from the outer edge of the disc.
Maximum disc runout: 0.05 mm (0.0020 in.)
(c) If the disc runout is greater than the maximum value,
check the bearing play in the axial direction and check the
axle hub runout (see page 30-2). If the bearing play and
axle hub runout are normal, adjust the disc runout or grind
it on a ºOn-carº brake lathe.
26. TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG
(a) Temporarily tighten the bleeder plug to the disc brake cylinder.
27. INSTALL FRONT DISC BRAKE BLEEDER PLUG CAP
28. INSTALL PISTON SEAL
(a) Install the piston seal (Single piston Type).
(1) Apply the lithium soap base glycol grease to a new piston seal.
(2) Install the piston seal to the disc brake cylinder.
(b) Install the 2 piston seals (Twin piston Type).
(1) Apply the lithium soap base glycol grease to the 2 new piston seals.
(2) Install the 2 piston seals to the disc brake cylinder.
29. INSTALL FRONT DISC BRAKE PISTON
(a) Install the front disc brake piston (Single piston Type).
(1) Apply the lithium soap base glycol grease to the piston.
(2) Install the piston to the disc brake cylinder.
NOTICE:
Do not screw the piston forcibly into the disc brake cylinder.
(b) Install the 2 front disc brake pistons (Twin piston Type).
(1) Apply the lithium soap base glycol grease to the 2 pistons.
(2) Install the 2 pistons to the disc brake cylinder.
NOTICE:
Do not screw the piston forcibly into the disc brake cylinder.
30. INSTALL CYLINDER BOOT
(a) Install the cylinder boot (Single piston Type).
(1) Apply the lithium soap base glycol grease to a new
cylinder boot.
(2) Install the cylinder boot to the disc brake cylinder.
HINT:
Install the boot securely to the grooves of the cylinder and pis-
ton.
(3) Using a screwdriver, install a new set ring.
NOTICE:
Do not damage the cylinder boot.

F41566
C68792
F41703
Anti squeal
Shim No.1
Anti squeal
Shim No.2
Anti squeal
Shim No.1
Wear Indicator
32-38
- BRAKEFRONT BRAKE
2472 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(b) Install the 2 cylinder boots (Twin piston Type).
(1) Apply the lithium soap base glycol grease to the 2
new cylinder boots.
(2) Install the 2 cylinder boots to the disc brake cylinder.
HINT:
Install the boot securely to the grooves of the cylinder and pis-
ton.
(3) Using a screwdriver, install the 2 new set rings.
NOTICE:
Do not damage the cylinder boot.
31. INSTALL FRONT DISC BRAKE BUSH DUST BOOT
(a) Place front disc brake cylinder mounting in vise.
(b) Apply the lithium soap base glycol grease to seal surface
of 2 new bush dust boots.
(c) Using a socket wrench (19 mm) and hammer, drive the 2
brake bush dust boots into the brake cylinder mounting.
32. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING LH
(a) Install the disc brake cylinder mounting with the 2 bolts.
Torque: 106.9 NVm (1,090 kgfVcm, 79 ftVlbf)
33. INSTALL FRONT DISC BRAKE CYLINDER SLIDE BUSH
(a) Apply the lithium soap base glycol grease to a new cylinder slide bush.
(b) Install the cylinder slide bush to the cylinder slide pin.
34. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN
(a) Apply the lithium soap base glycol grease to the sliding part and the seal surface of the 2 cylinder slide
pins.
(b) Install the 2 cylinder slide pins to the disc brake cylinder mounting.
HINT:
Install the cylinder slide pin with cylinder slide bush into the bottom side.
35. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE
(a) Install the bottom side front disc brake pad support plate.
36. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE
(a) Install the upper side front disc brake pad support plate.
37. INSTALL ANTI SQUEAL SHIM KIT FRONT
(a) Install the anti squeal shim kit front (Single piston Type).
(1) 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.

320E7-03
F41864Disc brake grease Lithium soap base glycol grease
Non-reusable part


NVm (kgfVcm, ftVlbf)
: Specified torque Rear LH
Flexible Hose Union Bolt

Gasket
Rear Disc Brake
Cylinder Slide Pin
Rear Disc Brake
Cylinder Slide Bush
Rear Disc Brake
Bleeder Plug
Rear Disc Brake
Bleeder Plug Cap
Disc Brake Cylinder
Assy Rear LH

Piston Seal
Rear Disc Brake
Disc Brake Piston

Cylinder Boot

Set Ring
Rear Disc Brake
Bush Dust Boot
Rear Disc Brake
Cylinder Slide Pin
Rear Disc Brake
Pad Support Plate
Rear Disc Brake
Cylinder Mounting LH
Anti Squeal
Shim No.1
Disc Brake
Pad Kit Rear Disc Brake
Pad Kit Rear
Parking Brake Shoe
Adjusting Hole Plug
Rear DiscAnti Squeal
Shim No.2 Wear Indicator Anti Squeal
Shim No.2
Anti Squeal
Shim No.1
Wear Indicator



61.8 (630, 46)
61.8 (630, 46)
39.2 (400, 29)
29.4 (300, 22)
34.3 (350, 25)
8.3 (85, 74 in.Vlbf)
32-40
- BRAKEREAR BRAKE
2474 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
REAR BRAKE
COMPONENTS

F41549
F41551
F41535
F41552
32-42
- BRAKEREAR BRAKE
2476 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
7. REMOVE REAR DISC BRAKE BUSH DUST BOOT
(a) Remove the bush dust boot from the cylinder slide pin.
8. REMOVE REAR DISC BRAKE CYLINDER SLIDE PIN
(a) Using a hexagon wrench (8 mm), remove the cylinder
slide pin.
9. REMOVE DISC BRAKE PAD KIT REAR (PAD ONLY)
(a) Remove the 2 brake pads with anti squeal shims.
10. REMOVE REAR DISC BRAKE ANTI SQUEAL SHIM KIT
(a) Remove the 2 anti squeal shims from 2 brake pads.
(b) Using a screwdriver, remove the wear indicator from 2
brake pads.
11. REMOVE REAR DISC BRAKE PAD SUPPORT PLATE
(a) Remove the upper side rear disc brake pad support plate.
12. REMOVE REAR DISC BRAKE PAD SUPPORT PLATE
(a) Remove the bottom side rear disc brake pad support plate.
13. REMOVE REAR DISC BRAKE CYLINDER MOUNTING
LH
(a) Remove the 2 bolts and disc brake cylinder mounting.

F41553
C82872
F41541
- BRAKEREAR BRAKE
32-43
2477 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
14. REMOVE CYLINDER BOOT
(a) Using a screwdriver, remove the set ring and cylinder boot
from the disc brake cylinder.
15. REMOVE REAR DISC BRAKE PISTON
(a) Place a piece of cloth or like, between the piston and the
disc brake cylinder.
(b) 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.
16. REMOVE PISTON SEAL
(a) Using a screwdriver, remove the piston seal from the disc brake cylinder.
NOTICE:
Do not damage the inner cylinder and the cylinder groove.
17. REMOVE REAR DISC BRAKE BLEEDER PLUG CAP
18. REMOVE REAR DISC BRAKE BLEEDER PLUG
19. INSPECT BRAKE CYLINDER AND PISTON
(a) Check the cylinder bore and piston for rust or scoring.
20. INSPECT PAD LINING THICKNESS
(a) Using a ruler, measure the pad lining thickness.
USA, Canada models:
Standard thickness: 10.0 mm (0.394 in.)
Minimum thickness: 1.0 mm (0.039 in.)
Brazil models:
Standard thickness: 11.0 mm (0.433 in.)
Minimum thickness: 1.0 mm (0.039 in.)
21. INSPECT REAR DISC BRAKE PAD SUPPORT PLATE
(a) Make sure that they have sufficient rebound, no deformation cracks or wear, and all rust, dirt are
cleaned off.
22. INSPECT REAR DISC BRAKE PAD SUPPORT PLATE
(a) Make sure that they have sufficient rebound, no deformation cracks or wear, and all rust, dirt are
cleaned off.