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Home >> Lexus >> 2003 >> ES 300 V6-3.0L (1MZ-FE) >> Repair and Diagnosis >> Brakes and Traction Control >> Disc Brake System >> Service and Repair >> Front

Front

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Part 2 Of 2:






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 ASSEMBLY 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 cylinder mounting.





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).
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 certain 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.





19. INSPECT PAD LINING THICKNESS
a. Using a ruler, measure the pad lining thickness.
Single piston type:
Standard thickness: 12.0 mm (0.472 inch)
Minimum thickness: 1.0 mm (0.039 inch)
Twin piston type:
Standard thickness: 10.6 mm (0.417 inch)
Minimum thickness: 1.0 mm (0.039 inch)
20. INSPECT FRONT 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.
21. INSPECT FRONT 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 DISC THICKNESS
a. Using a micrometer, measure the disc thickness.
Standard thickness: 28.0 mm (1.102 inch)
Minimum thickness: 26.0 mm (1.024 inch)





23. REMOVE FRONT DISC
a. Put matchmark on the disc and the axle hub.
b. Remove the disc.
24. INSTALL FRONT DISC
a. Aligning the matchmark, install the front disc.

HINT: When replacing the disc with a new one, select the installation position where the disc has the minimum runout.





25. INSPECT DISC RUNOUT
a. Temporarily install the disc with hub nuts.
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
b. Using a dial indicator, measure the disc runout 10 mm (0.39 inch) away from the outer edge of the disc.
Maximum disc runout: 0.05 mm (0.0020 inch)
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. If the bearing play and axle hub runout are normal, adjust the disc runout or grind it on a "On-car" brake lathe.
26. TEMPORARY 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 piston.

3. Using a screwdriver, install a new set ring.

NOTICE: Do not damage the cylinder boot.





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 piston.

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 Nm (1,090 kgf-cm, 79 ft. lbs.)
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.
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 ASSEMBLY LH
a. Install the disc brake cylinder with the 2 bolts.
Torque: 34.3 Nm (350 kgf-cm, 25 ft. lbs.)
40. CONNECT FRONT FLEXIBLE HOSE
a. Connect a new gasket and flexible hose with the union bolt.
Torque: 29.4 Nm (300 kgf-cm, 22 ft. lbs.)

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
SST 09023-00100
43. BLEED BRAKE LINE
44. CHECK FLUID LEVEL IN RESERVOIR
45. CHECK BRAKE FLUID LEAKAGE
46. INSTALL FRONT WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)

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