Lexus Car ES, IS, LS 1998-06

Brake Caliper

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Front wheels
     
    Brake line at the caliper
     
    2 bolts to the holding the caliper to the steering knuckle
     
    Caliper assembly
     

  4.  

To install:

  1. Install or connect the following:

    Caliper. Tighten the 2 bolts to 87 ft. lbs. (118 Nm).
     
    Brake line with 2 new gaskets and tighten the union to 29 ft. lbs. (39 Nm)
     

  2.  
  3. Refill the reservoir as necessary and bleed the brake system.
  4.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Install or connect the following:

    Wheels
     
    Brake line at the caliper by removing the union bolt and 2 gaskets
     
    Mounting bolts, while holding the sliding pin with a wrench
     
    Caliper from the caliper support
     

  4.  

To install:

  1. Install or connect the following:

    Caliper to the caliper support
     
    Caliper bolts. Hold the sliding pin and tighten the mounting bolts to 25 ft. lbs. (34 Nm).
     
    Brake line with (2) new gaskets and tighten the union to 22 ft. lbs. (30 Nm)
     

  2.  
  3. Bleed the brake system.

    Wheels
     

  4.  
  5. Check and fill the master cylinder reservoir, if needed.
  6.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove the front wheels.
  4.  
  5. Disconnect the brake line at the caliper.
  6.  
  7. Remove the 2 bolts to the holding the caliper to the steering knuckle and remove the caliper assembly.
  8.  

To install:

  1. Install the caliper. Install the 2 bolts and torque to 87 ft. lbs. (118 Nm).
  2.  
  3. Connect the brake line with 2 new gaskets and tighten the union to 29 ft. lbs. (39 Nm).
  4.  
  5. Refill the reservoir as necessary and bleed the brake system.

    Click image to see an enlarged view

    Fig. Front disc brakes-LS400

  6.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove the front wheels.
  4.  
  5. Remove the 2 bolts holding the caliper to the steering knuckle and remove the caliper.
  6.  
  7. Remove the brake pads and retainers.
  8.  

To install:

  1. Install the pad support plates and the pad wear indicator plate on the inside pad.
  2.  
  3. Install both pads with the wear indicator plates.
  4.  
  5. Compress the caliper pistons and install the caliper.
  6.  
  7. Install the 2 bolts to hold the caliper to the steering knuckle. Torque the bolts to 87 ft. lbs. (118 Nm).
  8.  
  9. Install the front wheels.
  10.  
  11. Check the fluid level in the reservoir.
  12.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain 23 of the brake fluid from the front reservoir. Use the bleeder screw at the front outlet port to drain the fluid. If equipped with anti-lock brakes, relieve the system pressure.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Remove the wheels.
  8.  
  9. Insert a small prybar through the caliper opening and pry the caliper (using the outboard brake pad) to bottom the pistons in the caliper bore.
  10.  


NOTE
This will back the brake pads off of the rotor surface to facilitate the removal and installation of the caliper assembly.

  1. Remove the brake hose-to-caliper bolt, hose and washers.
  2.  
  3. Remove both caliper slide pin bushing caps and slide pins.
  4.  
  5. Lift the caliper from the anchor.
  6.  

To install:

  1. Position the caliper into place on the anchor.
  2.  
  3. Coat the caliper slide pins with silicone grease and torque them to 53 ft. lbs. (72 Nm). Install the slide pin bushing caps.
  4.  
  5. Using new gasket washers, install the brake line and torque the fitting bolt to 23 ft. lbs. (31 Nm).
  6.  
  7. Fill the master cylinder with fluid and bleed the brake system.
  8.  
  9. Before driving the vehicle, pump the brakes several times to seat the pads.
  10.  
  11. Install the wheels.
  12.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Wheels
     
    Brake hose from the caliper
     
    Bolts that attach the caliper to the torque plate
     
    Caliper assembly by lifting the bottom
     

  4.  

To install:

  1. Grease the caliper slides and bolts with lithium grease.
  2.  
  3. Install or connect the following:

    Caliper. Torque the bolts to 25 ft. lbs. (34 Nm).
     
    Brake hose to the caliper using 2 new washers. Torque the union bolt to 20 ft. lbs. (29 Nm).
     

  4.  
  5. Fill the master cylinder to the proper level and bleed the brake system.

    Click image to see an enlarged view

    Fig. Front disc brakes-ES 300

  6.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Wheels
     
    Brake hose from the caliper
     
    Bolts that attach the caliper to the torque plate
     
    Caliper assembly by lifting the bottom
     

  4.  

To install:

  1. Grease the caliper slides and bolts with lithium grease.
  2.  
  3. Install or connect the following:

    Caliper. Torque the bolts to 25 ft. lbs. (34 Nm).
     
    Brake hose to the caliper using 2 new washers. Torque the union bolt to 22 ft. lbs. (30 Nm).
     

  4.  
  5. Fill the master cylinder to the proper level and bleed the brake system.

    Click image to see an enlarged view

    Fig. Front disc brakes-IS 300

  6.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Wheels
     
    Brake hose from the caliper
     
    Bolts that attach the caliper to the mounting bracket
     
    Caliper assembly by lifting the bottom
     

  4.  

To install:

  1. Grease the caliper slides and bolts with lithium grease.
  2.  
  3. Install or connect the following:

    Caliper. Hold the sliding pin and tighten the mounting bolts to 25 ft. lbs. (34 Nm).
     
    Brake hose to the caliper using 2 new washers. Torque the union bolt to 22 ft. lbs. (30 Nm)
     
    Wheels
     

  4.  
  5. Fill the master cylinder to the proper level and bleed the brake system.
  6.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Wheels
     
    Hole pin hold clip
     
    Front disc brake anti-rattle with hole pin while pushing on the anti-rattle spring
     
    Anti-rattle spring
     
    2 pads and the 2 anti-squeal shims from each pad
     
    Brake hose from the caliper
     
    Bolts that attach the caliper to the steering knuckle
     
    Caliper assembly by lifting the bottom
     

  4.  

To install:

  1. Install or connect the following:

    Caliper. Torque the bolts to 58 ft. lbs. (78 Nm)
     
    Brake hose to the caliper using 2 new washers. Torque the union bolt to 29 ft. lbs. (39 Nm)
     
    2 pads and the 2 anti-squeal shims to each pad
     
    Anti-rattle spring
     
    Hole pin while pushing on the front disc brake anti-rattle spring
     
    Hole pin hold clip
     
    Wheels
     

  2.  
  3. Fill the master cylinder to the proper level and bleed the brake system.

    Click image to see an enlarged view

    Fig. Front disc brakes-IS 350

  4.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    Do not disconnect the pad wear indicator unless you are replacing the brake pads.



    Front wheels
     
    Clip and 2 pins
     
    Anti-rattle spring
     
    2 pads with anti-squeal shims and spacers
     

  4.  
  5. Remove the union bolt and gasket from the caliper, then disconnect the brake hose from the caliper. Use a container to catch the brake fluid as it drains out.
  6.  
  7. Remove the 2 bolts and caliper from the knuckle.
  8.  

To install:

  1. Install the brake caliper to the knuckle. Tighten the 2 bolts to 87 ft. lbs. (118 Nm).
  2.  
  3. Connect the brake hose to the caliper and install the gasket and union bolt. Tighten the bolt to 29 ft. lbs. (39 Nm). Install the flexible hose lock securely in the lock hole in the caliper.
  4.  
  5. Install or connect the following:

    2 pads with anti-squeal shims and spacers
     
    Anti-rattle spring
     
    Clip and 2 pins
     
    Front wheels
     

  6.  
  7. Refill the reservoir as necessary and bleed the brake system.
  8.  
  9. Check for fluid leakage.
  10.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Front wheels
     
    Brake line at the caliper
     
    2 bolts to the holding the caliper to the steering knuckle
     
    Caliper assembly
     

  4.  

To install:

  1. Install or connect the following:

    Caliper. Tighten the 2 bolts to 77 ft. lbs. (104 Nm)
     
    Brake line with 2 new gaskets and tighten the union to 29 ft. lbs. (39 Nm)
     

  2.  
  3. Refill the reservoir as necessary and bleed the brake system.
  4.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Install or connect the following:

    Wheels
     
    Brake line at the caliper by removing the union bolt and 2 gaskets
     
    Mounting bolts, while holding the sliding pin with a wrench
     
    Caliper from the caliper support
     

  4.  

To install:

  1. Install or connect the following:

    Caliper to the caliper support
     
    Caliper bolts. Hold the sliding pin and tighten the mounting bolts to 25 ft. lbs. (34 Nm).
     
    Brake line with (2) new gaskets and tighten the union to 22 ft. lbs. (30 Nm)
     

  2.  
  3. Bleed the brake system.

    Wheels
     

  4.  
  5. Check and fill the master cylinder reservoir, if needed.
  6.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Wheels
     
    Brake hose from the caliper
     
    Bolts that attach the caliper to the torque plate
     
    Caliper assembly by lifting the bottom
     

  4.  

To install:

  1. Grease the caliper slides and bolts with lithium grease.
  2.  
  3. Install or connect the following:

    Caliper. Torque the bolts to 25 ft. lbs. (34 Nm).
     
    Brake hose to the caliper using 2 new washers. Torque the union bolt to 21 ft. lbs. (29 Nm).
     

  4.  
  5. Fill the master cylinder to the proper level and bleed the brake system.
  6.  


    Click image to see an enlarged view

    Fig. Front disc brakes-ES 300


  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove the wheels.
  4.  
  5. Disconnect the brake hose from the caliper.
  6.  
  7. Remove the bolts that attach the caliper to the torque plate.
  8.  
  9. Lift the bottom of the caliper up and remove the caliper assembly.
  10.  

To install:

  1. Grease the caliper slides and bolts with lithium grease. Install the caliper. Torque the bolts to 25 ft. lbs. (34 Nm).
  2.  
  3. Reconnect the brake hose to the caliper using 2 new washers. Torque the union bolt to 21 ft. lbs. (29 Nm).
  4.  
  5. Fill the master cylinder to the proper level and bleed the brake system.

    Click image to see an enlarged view

    Fig. Front disc brakes-ES300

  6.  

 
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