Lexus ES manuals

Lexus ES: Reassembly

Lexus ES (XZ10) Service Manual / Brake / Brake (rear) / Rear Brake / Reassembly

REASSEMBLY

CAUTION / NOTICE / HINT

CAUTION:

If the rear disc brake cylinder assembly has been disassembled, perform air bleeding for the rear disc brake cylinder assembly.

for HV Model: Click here

for Gasoline Model: Click here

NOTICE:

  • Make sure not to scratch, damage or apply excessive force to any of the internal components of the rear disc brake cylinder.
  • To prevent rusting on the inside of the rear disc brake cylinder, perform the rear disc brake piston removal and installation quickly.
  • Do not clean the interior of the rear disc brake cylinder with brake cleaner.
  • Do not remove any parts unless specifically instructed to do so, and only remove the parts indicated.

PROCEDURE

1. TEMPORARILY TIGHTEN REAR DISC BRAKE BLEEDER PLUG

(a) Temporarily install the rear disc brake bleeder plug to the rear disc brake cylinder.

HINT:

Fully tighten the rear disc brake bleeder plug after bleeding the system.

2. INSTALL REAR DISC BRAKE BLEEDER PLUG CAP

(a) Install the rear disc brake bleeder plug cap to the rear disc brake bleeder plug.

3. INSTALL PISTON SEAL

(a) Apply lithium soap base glycol grease to the entire circumference of a new piston seal.

Lithium Soap Base Glycol Grease

(b) Install the piston seal to the rear disc brake cylinder.

NOTICE:

  • Do not damage the inner surface or piston seal groove of the rear disc brake cylinder.
  • Do not allow the nut to rotate. If the nut is accidentally allowed to rotate, return it to its original position.

4. INSTALL REAR DISC BRAKE PISTON

(a) Apply a light layer of lithium soap base glycol grease to the entire circumference of a new cylinder boot.

*1

Cylinder Boot

*2

Rear Disc Brake Piston

Lithium Soap Base Glycol Grease

(b) Apply a light layer of lithium soap base glycol grease to the contact surfaces of the rear disc brake piston.

(c) Install the cylinder boot to the rear disc brake piston.

NOTICE:

The front and back sides of the cylinder boot are different. Make sure not to install the cylinder boot backwards.

*a

Front Side

*b

Back Side

(d) Install the rear disc brake piston to the rear disc brake cylinder.

NOTICE:

  • Install the rear disc brake cylinder so that its portions marked (A) fit into the indentations of the rear disc brake piston.
  • Do not forcibly install the rear disc brake piston into the rear disc brake cylinder.

*a

Indentations

(e) Install the cylinder boot to the rear disc brake cylinder as shown in the illustration.

NOTICE:

  • Do not damage the cylinder boot.
  • Securely install the cylinder boot into the groove of the rear disc brake cylinder and groove of the rear disc brake piston.

*1

Cylinder Boot

*2

Rear Disc Brake Cylinder

*3

Rear Disc Brake Piston

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