Lexus ES300 (1997 year). Manual — part 284

BR06M–01

R02840

–

BRAKE

FRONT BRAKE CALIPER

BR–27

1142

1997 LEXUS ES300 (RM511U)

REMOVAL

1.

REMOVE FRONT WHEEL

2.

DISCONNECT FLEXIBLE HOSE

(a)

Remove the union bolt and 2 gaskets from the caliper,
then disconnect the flexible hose from the caliper.
Torque: 29 N·m (300 kgf·cm, 21 ft·lbf)

HINT:
At the time of installation, please refer to the following item.
Install the flexible hose lock securely in the lock hole in the cali-
per.
(b)

Use a container to catch the brake fluid as it drains out.

3.

REMOVE CALIPER

(a)

Remove the 2 installation bolts.
Torque: 34 N·m (350 kgf·cm, 25 ft·lbf)

(b)

Remove the caliper from the torque plate.

4.

REMOVE THESE PARTS:

(a)

2 brake pads with anti–squeal shims

(b)

2 pad support plates

BR06N–01

R00121

R00122

R00123

R02877

BR–28

–

BRAKE

FRONT BRAKE CALIPER

1143

1997 LEXUS ES300 (RM511U)

DISASSEMBLY

1.

REMOVE SET RING AND CYLINDER BOOT

Using a screwdriver, remove the set ring and cylinder boot from
the caliper.

2.

REMOVE PISTON

(a)

Place a piece of cloth or similar, between the piston and
the caliper.

(b)

Use compressed air to remove the piston from the cylin-
der.

CAUTION:
Do not place your fingers in front of the piston when using
compressed air.

3.

REMOVE PISTON SEAL

Using a screwdriver, remove the piston seal from the cylinder.

4.

REMOVE SLIDING PINS AND DUST BOOTS

(a)

Remove the 2 sliding pins from the torque plate.

NOTICE:
At the time of reassembly, please refer to the following
item. Insert the sliding pin with sliding bushing into the top
side.
(b)

Using a screwdriver and hammer, tap out the 2 dust
boots.

HINT:
At the time of reassembly, please refer to the following item. Use
a 24 mm socket wrench and tap in 2 new dust boots into the
torque plate.
NOTICE:
At the time of reassembly, please refer to the following
item. Check that the metal plate portion of the dust boot fits
snugly in the torque plate.

BR06O–03

R02951

R02878

R02879

R02880

–

BRAKE

FRONT BRAKE CALIPER

BR–29

1144

1997 LEXUS ES300 (RM511U)

INSPECTION

1.

MEASURE PAD LINING THICKNESS

Using a ruler, measure the pad lining thickness.

Standard thickness: 11.0 mm (0.433 in.)
Minimum thickness: 1.0 mm (0.039 in.)

Replace the pad if the pad’s thickness is at the minimum thick-
ness or less, or if the pad has severe and uneven wear.

2.

MEASURE DISC THICKNESS

Using a micrometer, measure the disc thickness.

Standard thickness: 28.0 mm (1.102 in.)
Minimum thickness: 26.0 mm (1.024 in.)

Replace the disc if the disc’s thickness is at the minimum thick-
ness or less. Replace the disc or grind it on a lathe if it is badly
scored or worn unevenly.

3.

MEASURE DISC RUNOUT

Using a dial indicator, measure disc runout 10 mm (0.39 in.)
away from the outer edge of the disc.

Maximum disc runout: 0.05 mm (0.0020 in.)

If the disc’s runout is the maximum value or greater, check the
bering play in the axial direction and check the axle hub runout
(See page

SA–9

). If the bearing play and axle hub runout are

not abnormal, adjust the disc runout or grind it on a ”On–Car”
brake lathe.

4.

IF NECESSARY, ADJUST DISC RUNOUT

(a)

Remove the torque plate from the knuckle.

(b)

Remove the hub nuts and the disc. Reinstall the disc in
the position turned 1/5 from its original position on the
hub. Install and torque the hub nuts.
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)

Remeasure the disc runout. Make a note of the runout and the
disc’s position on the hub.
(c)

Repeat (b) until the disc has been installed on the 3 re-
maining hub positions.

(d)

If the minimum runout recorded in (b) and (c) is less than
0.05 mm (0.0020 in.), install the disc in that position.

(e)

If the minimum runout recorded in (b) and (c) is greater
than 0.05 mm (0.0020 in.), replace the disc and repeat
step 3.

(f)

Install the torque plate and torque the mounting bolts.
Torque: 107 N·m (1,090 kgf·cm, 79 ft·lbf)

BR06P–01

BR–30

–

BRAKE

FRONT BRAKE CALIPER

1145

1997 LEXUS ES300 (RM511U)

REASSEMBLY

Reassembly is in the reverse order of disassembly (See page

BR–28

).

NOTICE:
Apply lithium soap base glycol grease to the parts indicated by arrows (See page

BR–26

).