Lexus GS300/400 (2000 year). Service manual - part 102

BR0JR–07

F06932

 Gasket

Piston

Piston Seal

Brake Disc

Pad Guide Pin

Cylinder Boot

Inner Anti–squeal Shim

Non–reusable part
Lithium soap base glycol grease
Disc brake grease

: Specified torque

30 (310, 22)

Set Ring

Anti–squeal Shim

Anti–squeal Spring

Anti–squeal Shim

Brake Caliper

Inner Anti–squeal Shim

Outer Pad

Inner Pad

104 (1,065, 77)

Clip

N·m

 

(kgf·cm, ft·lbf)

–

BRAKE

REAR BRAKE CALIPER

BR–27

2135

REAR BRAKE CALIPER

COMPONENTS

BR0JS–06

F01639

BR–28

–

BRAKE

REAR BRAKE CALIPER

2136

REMOVAL

1.

REMOVE REAR WHEEL
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)

2.

DISCONNECT FLEXIBLE HOSE

Remove the union bolt and gasket from the caliper, then discon-
nect the flexible hose from the caliper. Use a container to catch
brake fluid as it drains out.

Torque: 30 N·m (310 kgf·cm, 22 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.
3.

REMOVE CALIPER

(a)

Remove the 2 installation bolts.
Torque: 104 N·m (1,065 kgf·cm, 77 ft·lbf)

(b)

Remove the caliper.

4.

REMOVE BRAKE PADS (See page 

BR–25

)

(a)

Remove the anti–squeal spring.

(b)

Remove the clip and pad guide pin.

(c)

Remove the 2 pads with the 4 anti–squeal shims.

BR0JT–03

F01640

Z09008

150 mm
(5.91 in.)

50 mm
(1.97 in.)

12 mm
(0.472 in.)

F01641

F01642

–

BRAKE

REAR BRAKE CALIPER

BR–29

2137

DISASSEMBLY

1.

REMOVE SET RINGS AND BOOTS

Using a screwdriver, remove the 2 set rings and 2 boots.

2.

REMOVE PISTONS FROM CYLINDER

(a)

Prepare a wooden plate to hold the pistons.

(b)

Place the plate between the pistons and insert a pad on
one side.

(c)

Use compressed air to remove the pistons alternately
from the caliper.

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

3.

REMOVE PISTON SEALS

Using a screwdriver, remove the 2 piston seals from the caliper.

BR0JU–07

F01643

F01644

F01645

BR–30

–

BRAKE

REAR BRAKE CALIPER

2138

INSPECTION

1.

MEASURE PAD LINING THICKNESS

Using a ruler, measure the pad lining thickness.

Standard thickness: 10.5 mm (0.413 in.)
Minimum thickness: 1.0 mm (0.039 in.)

Replace the pads if the thickness is less than the minimum or
if it shows signs of uneven wear.

2.

MEASURE DISC THICKNESS

Using a micrometer, measure the disc thickness.

Standard thickness: 12.0 mm (0.472 in.)
Minimum thickness: 10.5 mm (0.413 in.)

Replace the disc if the thickness of the disc is at the minimum
thickness 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 the disc runout at a position 10
mm (0.394 in.) away from the out side edge.

Maximum disc runout: 0.05 mm (0.0020 in.)

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

SA–44

). 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 3 hub nuts and disc. Turn the disc 1/5 and
reinstall the disc. Install and torque the 3 hub nuts.
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)

(b)

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.