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Home >> Lexus >> 2005 >> ES 330 V6-3.3L (3MZ-FE) >> Repair and Diagnosis >> Brakes and Traction Control >> Disc Brake System >> Service and Repair >> Rear

Rear






OVERHAUL

HINT:
^ Overhaul the RH side by the same procedures with LH side.
^ Two types of brake pad exist; one is with slit and the other without slit.

1. REMOVE REAR WHEEL
2. DRAIN BRAKE FLUID

NOTICE: Wash the brake fluid off immediately if it comes into contact with any painted surfaces.

3. DISCONNECT REAR LH 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 REAR DISC BRAKE CYLINDER SLIDE PIN
a. Remove the rear disc brake cylinder slide pin.





5. REMOVE DISC BRAKE CYLINDER ASSEMBLY REAR LH
a. Lift up the disc brake cylinder and remove the disc brake cylinder.





6. REMOVE REAR DISC BRAKE CYLINDER SLIDE BUSH
a. Remove the cylinder slide bush from the disc brake cylinder.





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.





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 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





20. INSPECT PAD LINING THICKNESS
a. Using a ruler, measure the pad lining thickness.
USA, Canada models:
Standard thickness: 10.0 mm (0.394 inch)
Minimum thickness: 1.0 mm (0.039 inch)
Brazil models:
Standard thickness: 11.0 mm (0.433 inch)
Minimum thickness: 1.0 mm (0.039 inch)
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.





23. INSPECT DISC THICKNESS
a. Using a micrometer, measure the disc thickness.
USA, Canada models:
Standard thickness: 12.0 mm (0.472 inch)
Minimum thickness: 10.5 mm (0.413 inch)
Brazil models:
Standard thickness: 10.0 mm (0.394 inch)
Minimum thickness: 8.5 mm (0.335 inch)
24. REMOVE PARKING BRAKE SHOE ADJUSTING HOLE PLUG





25. REMOVE REAR DISC
a. Put matchmark on the disc and the axle hub.
b. Remove the disc.
26. INSTALL REAR DISC
a. Aligning the matchmark, install the rear disc.

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

27. INSTALL PARKING BRAKE SHOE ADJUSTING HOLE PLUG





28. 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: 0.15 mm (0.0059 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.
29. ADJUST PARKING BRAKE SHOE CLEARANCE
30. TEMPORARY TIGHTEN REAR DISC BRAKE BLEEDER PLUG
a. Temporarily tighten the bleeder plug to the disc brake cylinder.
31. INSTALL REAR DISC BRAKE BLEEDER PLUG CAP
32. INSTALL PISTON SEAL
a. Apply the lithium soap base glycol grease to a new piston seal.
b. Install the piston seal to the disc brake cylinder.
33. INSTALL REAR DISC BRAKE DISC BRAKE PISTON
a. Apply the lithium soap base glycol grease to the piston.
b. Install the piston to the disc brake cylinder.

NOTICE: Do not screw the piston forcibly into the disc brake cylinder.





34. INSTALL CYLINDER BOOT
a. Apply the lithium soap base glycol grease to a new cylinder boot.
b. Install the cylinder boot to the disc brake cylinder.

HINT: Install the boot securely to the grooves of the cylinder and piston.

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

NOTICE: Do not damage the cylinder boot.

35. INSTALL REAR DISC BRAKE CYLINDER MOUNTING LH
a. Install the disc brake cylinder mounting with the 2 bolts.
Torque: 61.8 Nm (630 kgf-cm, 46 ft. lbs.)
36. INSTALL REAR DISC BRAKE PAD SUPPORT PLATE
a. Install the bottom side rear disc brake pad support plate.
37. INSTALL REAR DISC BRAKE PAD SUPPORT PLATE
a. Install the upper side rear disc brake pad support plate.





38. INSTALL REAR DISC BRAKE ANTI SQUEAL SHIM KIT
a. 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.
b. 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.

39. INSTALL DISC BRAKE PAD KIT REAR (PAD ONLY)
a. Install the 2 disc brake pads with the pad wear indicator facing downward.

NOTICE: There should be no oil or grease on the friction surface of the pads and the disc.





40. INSTALL REAR DISC BRAKE CYLINDER SLIDE PIN
a. Using a hexagon wrench (8 mm), install the cylinder slide pin.
Torque: 39.2 Nm (400 kgf-cm, 29 ft. lbs.)





41. INSTALL REAR DISC BRAKE BUSH DUST BOOT
a. Apply the lithium soap base glycol grease to seal surface of a new bush dust boot.
b. Install the bush dust boot to the cylinder slide pin.





42. INSTALL REAR 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 disc brake cylinder.
43. INSTALL DISC BRAKE CYLINDER ASSEMBLY REAR LH
a. Apply the lithium soap base glycol grease to the cylinder slide pin.
b. Install the disc brake cylinder to the cylinder slide pin.
44. INSTALL REAR DISC BRAKE CYLINDER SLIDE PIN
a. Apply the lithium soap base glycol grease to the cylinder slide pin.
b. Install the cylinder slide pin to the disc brake cylinder.
Torque: 34.3 Nm (350 kgf-cm, 25 ft. lbs.)
45. CONNECT REAR LH 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 hole of the disc brake cylinder.

46. FILL RESERVOIR WITH BRAKE FLUID
47. BLEED MASTER CYLINDER
SST 09023-00101
48. BLEED BRAKE LINE
49. CHECK FLUID LEVEL IN RESERVOIR
50. CHECK BRAKE FLUID LEAKAGE
51. INSTALL REAR WHEEL
Torque: 103 Nm (1050 kgf-cm, 76 ft. lbs.)

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