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Home >> Lexus >> 2010 >> IS 250 AWD V6-2.5L (4GR-FSE) >> Repair and Diagnosis >> Brakes and Traction Control >> Disc Brake System >> Service and Repair >> Overhaul >> Front Brake >> Reassembly

Reassembly





BRAKE: FRONT BRAKE (for 4GR-FSE): REASSEMBLY

1. INSTALL FRONT DISC

(a) for Type B:

(1) Check the identification mark to determine the installation side.





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NOTICE:
Correctly install the front disc by checking the mark "R" or "L" engraved on the back of it.

(b) Aligning the matchmarks, install the front disc.





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

2. TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG

(a) Temporarily tighten the front disc brake bleeder plug to the disc brake cylinder assembly.

3. INSTALL FRONT DISC BRAKE BLEEDER PLUG CAP

4. INSTALL PISTON SEAL

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





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

5. INSTALL FRONT DISC BRAKE PISTON

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





(b) Install the cylinder boot to the front disc brake piston.

(c) Apply a light layer of lithium soap base glycol grease to the contact surfaces of the front disc brake piston, and install it to the front disc brake cylinder assembly.

NOTICE:
Do not install the piston forcibly into the front disc brake cylinder assembly.

6. INSTALL CYLINDER BOOT

(a) Install the cylinder boot to the front disc brake cylinder assembly.





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

(b) Using a screwdriver with its tip wrapped with vinyl tape, install a new set ring.

NOTICE:
* Install the set ring securely to the grooves of the cylinder boot.
* Do not damage the cylinder boot.
7. INSTALL FRONT DISC BRAKE BUSHING DUST BOOT

(a) Secure the front disc brake cylinder mounting in a vise.

(b) Apply a light layer of lithium soap base glycol grease to the entire circumference of 2 new front disc brake bushing dust boots.





HINT
Apply at least 0.3 g (0.01 oz.) of lithium soap base glycol grease to each front disc brake bushing dust boot.

(c) Using a socket wrench (21 mm) and a hammer, install the 2 bushing dust boots to the front disc brake cylinder mounting.





8. INSTALL FRONT NO. 1 DISC BRAKE CALIPER PLATE

(a) Install 2 new front No. 1 disc brake caliper plates to the front disc brake cylinder mounting.

9. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING

(a) Install the front disc brake cylinder mounting with 2 new bolts.

Torque : 78 Nm (799 kgf-cm, 58 ft-lbf)

10. INSTALL FRONT NO. 2 DISC BRAKE CYLINDER SLIDE PIN

(a) Apply a light layer of lithium soap base glycol grease to the sliding part and the seal surface of the front No. 2 disc brake cylinder slide pin.





(b) Install the front No. 2 disc brake cylinder slide pin to the front disc brake cylinder mounting.

NOTICE:
Insert the front No. 2 disc brake cylinder slide pin into the front disc brake cylinder mounting lower side.

11. INSTALL FRONT DISC BRAKE CYLINDER SLIDE BUSHING

(a) Apply a light layer of lithium soap base glycol grease to the contact surface of the front No. 1 disc brake cylinder slide pin.





(b) Install a new front disc brake cylinder slide bushing to the front No. 1 disc brake cylinder slide pin.

12. INSTALL FRONT NO. 1 DISC BRAKE CYLINDER SLIDE PIN

(a) Apply a light layer of lithium soap base glycol grease to the sliding part and the seal surface of the front No. 1 disc brake cylinder slide pin.





(b) Install the front No. 1 disc brake cylinder slide pin to the front disc brake cylinder mounting.

NOTICE:
Insert the slide pin into the cylinder mounting LH upper side.

13. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE

(a) for Type A:

(1) Install the 2 front No. 1 disc brake pad support plates and 2 front No. 2 disc brake pad support plates to the front disc brake cylinder mounting.





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NOTICE:
Be sure to install each front disc brake pad support plate to the correct position and direction.

(b) for Type B:

(1) Install the front No. 1 disc brake pad support plate and front No. 2 disc brake pad support plate to the front disc brake cylinder mounting.





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NOTICE:
Be sure to install each front disc brake pad support plate to the correct position and direction.

14. INSTALL FRONT ANTI-SQUEAL SHIM

(a) for Type A:

(1) Apply disc brake grease between the front No. 1 anti-squeal shim and front No. 2 anti-squeal shim.





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NOTICE:
* When replacing worn pads, the front anti-squeal shims must be replaced together with the pads.
* Apply disc brake grease to the area that contacts the front anti-squeal shims.
* Make sure that disc brake grease is not applied onto the lining surface.
(2) Install the front No. 1 anti-squeal shim and front No. 2 anti-squeal shim to each front disc brake pad.

NOTICE:
* Disc brake grease can come out slightly from the area where the front anti-squeal shims are installed.
* Install the front anti-squeal shims in the correct positions and directions.
* There should be no oil or grease on the friction surfaces of the pads and disc.
(b) for Type B:

(1) Apply disc brake grease to both sides of the front No. 1 anti-squeal shim.





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NOTICE:
* When replacing worn pads, the front anti-squeal shims must be replaced together with the pads.
* Apply disc brake grease to the area that contacts the front anti-squeal shims.
* Make sure that disc brake grease is not applied onto the lining surface.
(2) Install the front No. 1 anti-squeal shim and front No. 2 anti-squeal shim to each front disc brake pad.

NOTICE:
* Disc brake grease can come out slightly from the area where the front anti-squeal shims are installed.
* Install the front anti-squeal shims in the correct positions and directions.
* There should be no oil or grease on the friction surfaces of the pads and disc.
* Install the front anti-squeal shim with attention to the direction of the grooves on the front disc brake pads.
* The front disc brake pads of the same part number are used for the inner and outer.
* The RH side pad is symmetrical to the LH side pad.
* Correctly install the front disc brake pads by checking the mark "R" or "L" engraved on the back of them.






15. INSTALL NO. 1 PAD WEAR INDICATOR PLATE

(a) Install the No. 1 pad wear indicator plate to each front disc brake pad.

NOTICE:
Install the pad wear indicator plates in the correct positions and directions.

16. INSTALL FRONT DISC BRAKE PAD

(a) Install the 2 front disc brake pads to the front disc brake cylinder mounting.
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