2005 LEXUS ES300 brake fluid

0103C-05
01-6- INTRODUCTIONTERMS FOR AUTOMATIC TRANSAXLE REPAIR
MANUAL
6 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
TERMS FOR AUTOMATIC TRANSAXLE REPAIR MANUAL
ABBREVIATIONS USED IN THIS MANUAL
AbbreviationsMeaning
ASSYAssembly
AT FAutomatic Transaxle Fluid
B3U/D Brake
C2Reverse Clutch
C3U/D Clutch
FIPGFormed In Place Gasket
O/DOverdrive
SSMSpecial Service Materials
SSTSpecial Service Tools
U/DUnderdrive
w/With
w/oWithout
1stFirst
2ndSecond

4005R-08
D25120
Add if hotOK if hot
- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE FLUID
40-1
2516 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
AUTOMATIC TRANSAXLE FLUID
ON-VEHICLE INSPECTION
1. CHECK THE FLUID LEVEL
HINT:
Drive the vehicle so that the engine and transaxle are at normal
operating temperature.
Fluid temperature: 70 - 80 °C (158 - 176 °F)
(a) Park the vehicle on a level surface and set the parking
brake.
(b) With the engine idling and the brake pedal depressed,
shift the shift lever into all positions from P to L position,
and return to P position.
(c) take out the dipstick and wipe it clean.
(d) Put it back fully into the pipe.
(e) take it out and check that the fluid level is in the HOT posi-
tion.
If there are leaks, it is necessary to repair or replace O-rings,
FIPGs, oil seals, plugs and/or other parts.

400FX-04
40-2
- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY
2517 Author
: Date
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
AUTOMATIC TRANSAXLE ASSY
PRECAUTION
1. The automatic transaxle is composed of highly precision-finished parts, if nequine careful in-
spection before reassembly therefore even a small nick may cause fluid leakage or may de-
grade the performance. The instructions here are organized so that you work on only one com-
ponent group at a time. This will help you to avoid confusion about similar-looking parts of
different sub-assemblies being on your workbench at the same time. The component groups
are inspected and repaired from the converter housing side. Inspectio, repair and reassembly
As much as possible, before proceeding to the next component group. If a defect is found in
a certain component group during reassembly, inspect and repair this group immediately. If a
component group cannot be assembled because parts are being ordered, be sure to keep all
parts of the group in a separate container while proceeding with disassembly, inspection, re-
pair and reassembly of other component groups.
Recommended ATF: T-IV
2. All disassembled parts should be washed clean and any fluid passages and holes should be
blown with compressed air.
3. Dry all parts with compressed airnever use shop rags.
4. When using compressed air, do not aim at yourself to prevent accidentally spraying ATF or ker-
osene on your face.
5. The recommended automatic transaxle fluid or kerosene should be used for cleaning.
6. After cleaning, the parts should be arranged in the correct order for efficient inspection, repairs,
and reassembly.
7. When disassembling a valve body, be sure to match each valve together with the correspond-
ing spring.
8. New discs for the brakes and clutches that are to be used for replacement must be soaked in
ATF for at least 15 minutes before reassembly.
9. All oil seal rings, clutch discs, clutch plates, rotating parts, and sliding surfaces should be
coated with ATF prior to reassembly.
10. All gaskets and rubber O-rings should be replaced.
11. Do not apply adhesive cements to gaskets and similar parts.
12. Make sure that the ends of a snap ring are not aligned with one of the cutouts and are installed
in the groove correctly.
13. If a worn bushing is to be replaced, the sub-assembly containing the bushing must also be re-
placed.
14. Check thrust bearings and races for wear or damage. Replace if necessary.
15. Use petroleum jelly to keep parts in place.
16. When working with FIPG material, you must perform the following.
Using a razor blade and a gasket scraper, remove all the old packing (FIPG) material from the
gasket surface.
Thoroughly clean all components to remove all the loose material.
Clean both sealing surfaces with a non-residue solvent.
Parts must be reassembled within 10 minutes of application. Otherwise, the packing (FIPG) ma-
terial must be removed and reapplied.

32039-18
32-2
- BRAKEBRAKE SYSTEM
2436 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
Low pedal or spongy pedal
2. Fluid leaks for brake system
3. Air in brake system
4. Piston seals (Worn or damaged)
5. Master cylinder (Fauly)
6. Booster push rod (Out of adjustment)-
32-4
32-33
32-41
32-21
32-8
32-12
Brake drag
1. Brake pedal free play (Minimal)
2. Parking brake pedal travel (Out of adjustment)
3. Parking brake wire (Sticking)
4. Parking brake shoe clearance (Out of adjustment)
5. Pad (Cracked or distorted)
6. Piston (Stuck)
7. Piston (Frozen)
8. Tension or return spring (Faulty)
9. Booster push rod (Out of adjustment)
10.Vacuum leaks for booster system
11. Master cylinder (Faulty)32-8
32-12
33-2
33-8
33-1 1
33-14
33-2
32-33
32-41
32-33
32-41
32-33
32-41
33-16
32-8
32-12
32-26
32-21
Brake pull
1. Piston (Stuck)
2. Pad (Oily)
3. Piston (Frozen)
4. Disc (Scored)
5. Pad (Cracked or distorted) 32-33
32-41
32-33
32-41
32-33
32-41
32-33
32-41
32-33
32-41
Hard pedal but brake inefficient
1. Fluid leaks for brake system
2. Air in brake system
3. Pad (Worn)
4. Pad (Cracked or distorted)
5. Pad (Oily)
6. Pad (Glanzed)
7. Disc (Scored)
8. Booster push rod (Out of adjustment)
9. Vacuum leaks for booster system-
32-4
32-33
32-41
32-33
32-41
32-33
32-41
32-33
32-41
32-33
32-41
32-8
32-12
32-26

3211W-03
F41694
F41695
F41696
C80826
32-4
- BRAKEBRAKE FLUID
2438 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
BRAKE FLUID (From July, 2003)
BLEEDING
HINT:
If any work is done on the brake system or if air in the brake lines is suspected, bleed the air from the system.
NOTICE:
Wash off the brake fluied immediately if it comes into contact with a painted surface.
1. FILL RESERVOIR WITH BRAKE FLUID
Fluid: SAE J1703 or FMVSS No. 116 DOT3
2. BLEED MASTER CYLINDER
HINT:
If the master cylinder has been disassembled or if the reservoir
becomes empty, bleed the air from the master cylinder.
(a) Remove the air cleaner assembly with hose.
(b) Disconnect the brake lines from the master cylinder.
SST 09023-00101
(c) Slowly depress the brake pedal and hold it.
(d) Block off the outer holes with your fingers, and release the
brake pedal.
(e) Repeat (c) and (d) 3 or 4 times.
(f) Install the air cleaner assembly with hose.
3. BLEED BRAKE LINE
(a) Connect the vinyl tube to the brake caliper.
(b) Depress the brake pedal several times, then loosen the
bleeder plug with the pedal held down.
(c) At the point when fluid stops coming out, tighten the
bleeder plug, then release the brake pedal.
(d) Repeat (b) and (c) until all the air in the fluid has been bled
out.
(e) Tighten the bleeder plug certainly.
Torque: 8.3 NVm (85 kgfVcm, 73 in.Vlbf)

G23361DLC3
Hand-held Tester
C80826
- BRAKEBRAKE FLUID
32-5
2439 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(f) Repeat the above procedure to bleed the air out of the
brake line for each wheel.
4. BLEED BRAKE ACTUATOR ASSY (W/ VSC)
NOTICE:
After performing the usual air bleeding in the brake system,
if the height or feel of the brake pedal cannot be obtained,
perform air bleeding in the brake actuator assy with a
hand-held tester by following procedures below.
(a) Depress the brake pedal more than 20 times with the en-
gine off.
(b) Connect the hand-held tester to the DLC3, then turn the
ignition switch to the ON position.
NOTICE:
Do not start the engine.
(c) Select ºAIR BLEEDINGº on the hand-held tester.
HINT:
Please refer to the Hand-Held Tester Operator's Manual for fur-
ther details.
(d) Bleed the air out of the regular brake line in ºStep1: In-
creaseº on the hand-held tester display.
NOTICE:

Perform the air bleeding by following the steps dis-
played on the hand-held tester.

Make sure that the brake fluid in the master cylinder
reservoir tank does not become empty.
(1) Connect the vinyl tube to either one of the bleeder
plugs.
(2) Depress the brake pedal several times, then loosen
the bleeder plug of one of the above wheels with the
pedal depressed.
(3) When fluid stops coming out, tighten the bleeder
plug, then release the brake pedal.
(4) Repeat (2) and (3) until all air in the fluid is complete-
ly bled out.
(5) Tighten the bleeder plug certainly.
Torque: 8.3 NVm (85 kgfVcm, 73 in.Vlbf)
(6) Repeat the above procedure to bleed the air out of
the brake line for each wheel.
(e) Bleed the air out of the suction line in ºStep2: Inhalationº
on the hand-held tester display.
NOTICE:

Perform the air bleeding by following the steps dis-
played on the hand-held tester.

Make sure that the brake fluid in the master cylinder
reservoir tank does not become empty.

32-6
- BRAKEBRAKE FLUID
2440 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(1) Connect the vinyl tube to the bleeder plug at the
right front wheel or the right rear wheel and loosen
the bleeder plug.
(2) Operate the brake actuator assy using the hand-
held tester to bleed the air.
NOTICE:

The operation stops automatically in 4 seconds.

At this time, be sure to release the brake pedal.
(3) Check that the operation has stopped, by referring
to the hand-held tester display.
(4) Repeat (2) and (3) until all the air in the fluid is com-
pletely bled out.
(5) Tighten the bleeder plug certainly.
Torque: 8.3 NVm (85 kgfVcm, 73 in.Vlbf)
(6) For the rest of the wheels, bleed the air in the same
way as stated in the above procedure.
(f) Bleed the air out of the pressure reduction line in ºStep3:
Decreaseº on the hand-held tester display.
NOTICE:

Perform air bleeding by following the steps displayed
on the hand-held tester.

Make sure that the brake fluid in the master cylinder
reservoir tank does not become empty.
(1) Connect a vinyl tube to either one of the bleeder
plugs.
(2) Loosen the bleeder plug.
(3) Using the hand-held tester, operate the brake ac-
tuator assy using hand-held tester, completely de-
press the brake pedal and keep it.
NOTICE:

The operation stops automatically in 4 seconds.
When performing this procedure continuously, an in-
terval of at least 20 seconds is required.

When the operation is completed, the brake pedal
slightly goes down. This is a normal phenomenon
caused when the solenoid opens.

During this procedure, the pedal seems heavy, but
completely depress it so that the brake fluid comes
out from the bleeder plug.

Be sure to keep depressing the brake pedal. Never
depress and release the pedal repeatedly.
(4) Tighten the bleeder plug, then release the brake
pedal.
(5) Repeat (2) to (4) until all the air in the fluid is com-
pletely bled out.
(6) Tighten the bleeder plug certainly.
Torque: 8.3 NVm (85 kgfVcm, 73 in.Vlbf)
(7) Repeat the above procedure to bleed the air out of
the brake line for each wheel.

C80826
F41007
- BRAKEBRAKE FLUID
32-7
2441 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(g) Bleed the air out of the regular brake line again in ºStep4:
Increaseº on the hand-held tester display.
NOTICE:

Perform air bleeding by following the steps displayed
on the hand-held tester.

Make sure that the brake fluid in the master cylinder
reservoir tank does not become empty.
(1) Connect the vinyl tube to either one of the bleeder
plug.
(2) Depress the brake pedal several times, then loosen
the bleeder plug of one of the above wheels with the
pedal depressed.
(3) When fluid stops coming out, tighten the bleeder
plug, then release the brake pedal.
(4) Repeat (2) and (3) until all the air in the fluid is com-
pletely bled out.
(5) Tighten the bleeder plug certainty.
Torque: 8.3 NVm (85 kgfVcm, 73 in.Vlbf)
(6) Repeat the above procedure to bleed the air out of
the brake line for each wheel.
5. CHECK FLUID LEVEL IN RESERVOIR
(a) Check the fluid level and add fluid if necessary.
Fluid: SAE J1703 or FMVSS No. 116 DOT3