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Home >> Lexus >> 2023 >> RX 500h >> Repair and Diagnosis >> Brakes >> Mechanical - Hydraulic >> Brake System (Rear) - Service Information >> Rear Brake >> Installation [10/2022 - ] >> Procedure

Installation [10/2022 - ]: Procedure

  1. INSTALL REAR DISC 
    1. GTY1129334Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Matchmark - -
      1. Align the matchmarks of the rear disc and rear axle hub and bearing assembly, and install the rear disc.
        NOTE:

        When replacing the rear disc with a new one, select the installation position where the rear disc has minimal runout.

      2. Using a 5 mm hexagon socket wrench, install the bolt.

        Torque: 20.0 N.m (204 kgf/cm, 15 ft.lbf) 

        NOTE:
        • Do not apply excessive force to the bolt and rear disc.
        • Confirm that the head of the bolt is not protruding from the surface of the disc.
  2. INSTALL REAR DISC BRAKE CYLINDER MOUNTING 
    1. GTY1123143Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using SST, fully tighten the 2 bolts.
        • SST: 09961-01270 

        Specified tightening torque 

        Torque: 215 N.m (2192 kgf/cm, 159 ft.lbf) 

        HINT: 

        • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

          Refer to PRECAUTION [10/2022 - ]

        • When using SST (fulcrum length of 200 mm (7.87 in.)) + torque wrench (fulcrum length of 400 mm (1.31 ft.)

          143.3 N.m (1461 kgf/cm, 106 ft.lbf)

  3. INSTALL REAR DISC BRAKE BUSH DUST BOOT 
    1. GTY1127153Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Lithium soap base glycol grease - -
      1. Apply a light layer of lithium soap base glycol grease to the entire circumference of 2 new rear disc brake bushing dust boots.

        HINT: 

        Apply more than 0.3 g (0.01 oz) of lithium soap base glycol grease to each rear disc brake bushing dust boot.

      2. Install the 2 rear disc brake bushing dust boots to the rear disc brake cylinder mounting.
  4. INSTALL REAR DISC BRAKE CYLINDER SLIDE BUSH 
    1. GTY1129001Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Lithium soap base glycol grease - -
      1. Apply a light layer of lithium soap base glycol grease to the contact surface of the rear disc brake cylinder slide pin (lower side).
      2. Install a new rear disc brake cylinder slide bushing to the rear disc brake cylinder slide pin (lower side).
  5. INSTALL REAR DISC BRAKE CYLINDER SLIDE PIN 
    1. GTY1124544Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Rear Disc Brake Cylinder Slide Pin (Upper Side) *2 Rear Disc Brake Cylinder Slide Pin (Lower Side)
      Lithium Soap Base Glycol Grease - -
      1. Apply a light layer of lithium soap base glycol grease to the sliding part and the sealing surfaces of the 2 rear disc brake cylinder slide pins.
      2. Install the 2 rear disc brake cylinder slide pins to the rear disc brake cylinder mounting.
      3. Push each rear disc brake cylinder slide pin into the rear disc brake bushing dust boot to engage the pin to the boot.
  6. INSTALL REAR DISC BRAKE PAD SUPPORT PLATE 
    NOTE:

    Be sure to install each rear disc brake pad support plate in the correct position and direction.
  7. INSTALL REAR DISC BRAKE ANTI SQUEAL SHIM KIT 
    Refer to PROCEDURE - Step 1
  8. INSTALL REAR DISC BRAKE PAD 
    1. GTY1254489Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A for TMC Made, 1Motor-HEV Model *B except TMC Made, 1Motor-HEV Model
      *a for TMC Made, 1Motor-HEV Model: Inner Side (Blue)
      except TMC Made, 1Motor-HEV Model: Inner Side (White)      		 *b Outer Side (White)
      1. Check the rear disc brake pad.

        HINT: 

        If the rear disc brake pad has an identification mark, be sure to confirm the installation location.

      2. Install the 2 rear disc brake pads to the rear disc brake cylinder mounting.
        NOTE:
        • Keep the friction surfaces of the rear disc brake pads and rear disc free from oil and grease.
        • Install the rear disc brake pad so that the rear disc brake pad wear indicator plate is mounted on the lower side of the vehicle.
  9. INSTALL REAR DISC BRAKE CYLINDER ASSEMBLY 
    1. GTY1129044Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Hold the 2 rear disc brake cylinder slide pins, and install the rear disc brake cylinder assembly to the rear disc brake cylinder mounting with 2 bolts.

        Torque: 34.3 N.m (350 kgf/cm, 25 ft.lbf) 

  10. INSTALL PARKING BRAKE ACTUATOR SEAL 
    Refer to PROCEDURE - Step 1
  11. INSTALL PARKING BRAKE ACTUATOR ASSEMBLY 
    Refer to PROCEDURE - Step 2
  12. CONNECT NO. 2 PARKING BRAKE WIRE ASSEMBLY 
    Refer to PROCEDURE - Step 3
  13. CONNECT REAR FLEXIBLE HOSE 
    1. GTY1124555Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Connect the rear flexible hose to the rear disc brake cylinder assembly with a new union bolt and a new gasket.

        Torque: 30.4 N.m (310 kgf/cm, 22 ft.lbf) 

        NOTE:

        Install the rear flexible hose lock securely into the lock hole in the rear disc brake cylinder assembly.

  14. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL (except Gasoline Model) 
    1. GTY1124221Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Connect the cable to the negative (-) auxiliary battery terminal.

        for 1Motor-HEV Model: Refer to INSTALLATION [10/2022 - ]

        except 1Motor-HEV Model: Refer to INSTALLATION [10/2022 - 08/2023] , or refer to INSTALLATION [08/2023 - ]

      2. Perform the following procedure if air bleeding is not necessary:
        1. Turn the ignition switch ON.
        2. Depress the brake pedal and release it.
        3. Clear the DTCs.

          Refer to DTC CHECK / CLEAR [10/2022 - ]

  15. BLEED BRAKE LINE 

    except Gasoline Model: Refer to BLEEDING [10/2022 - ]

    for Gasoline Model: Refer to BLEEDING [10/2022 - ]

  16. BLEED REAR DISC BRAKE CYLINDER ASSEMBLY (for Gasoline Model) 
    WARNING:

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

    HINT: 
    • Use the same procedure for the RH side and LH side.
    • The following procedure is for the LH side.
    • While performing air bleeding of the rear disc brake cylinder assembly, the bolts can be reused during the bleeding procedure. After air bleeding is complete, replace the bolts with new ones.
    1. GTY1065035Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Perform the following procedure:
        1. Perform the procedure to enter rear disc brake pad replacement mode 5 times.

          Refer to REAR BRAKE PAD REPLACEMENT MODE [10/2022 - ]

        2. Remove the brake master cylinder reservoir filler cap assembly.
        3. Force air within the rear disc brake cylinder assembly to accumulate at the rear disc brake bleeder plug.(*1)
          1. Disconnect the No. 2 parking brake wire assembly connector.

            Refer to PROCEDURE - Step 4

          2. Hold the 2 rear disc brake cylinder slide pins and remove the 2 bolts and separate the rear disc brake cylinder assembly from the rear disc brake cylinder mounting.
          3. Hold the rear disc brake cylinder assembly horizontally, then tilt it 45° toward the bleeder plug side as shown in the illustration.
          4. Temporarily install the rear disc brake cylinder assembly to the rear disc brake cylinder mounting with the 2 bolts.
          5. Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.
            NOTE:
            • Make sure that there is sufficient brake fluid in the reservoir.
            • Do not remove the filter from the brake master cylinder reservoir assembly and be sure to fill the brake master cylinder reservoir assembly with new brake fluid to avoid any potential contamination of the brake system. Contamination, for example by dirt particles or mineral oil, could lead to functional brake problems.
            • If brake fluid leaks onto any painted surface, immediately wash it off.
          6. Remove the rear disc brake bleeder plug cap.
          7. Connect a vinyl tube to the rear disc brake bleeder plug.
        4. Depress the brake pedal several times, and then loosen the rear disc brake bleeder plug with the pedal depressed.(*2)
        5. When fluid stops coming out, tighten the rear disc brake bleeder plug and release the brake pedal.(*3)
          NOTE:

          Repeat steps (*2) through (*3) until there are no signs of air in the brake fluid.

        6. Repeat steps (*1) through (*3) 3 times.
          NOTE:

          If there is still air in the system after performing steps (*1) through (*3) 3 times, repeat the steps (*1) through (*3) until the air has been bled.

        7. Tighten the rear disc brake bleeder plug completely.

          Torque

          8.3 N.m (85 kgf/cm, 6 ft.lbf)

        8. Install the rear disc brake bleeder plug cap to the rear disc brake bleeder plug.
        9. Hold the 2 rear disc brake cylinder slide pins, and install the rear disc brake cylinder assembly to the rear disc brake cylinder mounting with 2 new bolts.

          Torque

          34.3 N.m (350 kgf/cm, 25 ft.lbf)

        10. Connect the No. 2 parking brake wire assembly connector.

          Refer to PROCEDURE - Step 3

        11. Inspect the brake fluid level in the reservoir.

          Refer to ON-VEHICLE INSPECTION [10/2022 - ]

        12. Install the brake master cylinder reservoir filler cap assembly.
        13. Turn the ignition switch off.
        14. Clear the DTCs.

          Refer to DTC CHECK / CLEAR [10/2022 - ]

  17. BLEED REAR DISC BRAKE CYLINDER ASSEMBLY (except Gasoline Model) 
    WARNING:

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

    NOTE:
    • Perform air bleeding while maintaining the brake fluid level between the MAX and MIN lines on the brake fluid reservoir.
    • Do not allow brake fluid to contact any painted surface. If brake fluid leaks onto any painted surface, immediately wash it off.
    HINT: 
    • Use the same procedure for the RH side and LH side.
    • The following procedure is for the LH side.
    • While performing air bleeding of the rear disc brake cylinder assembly, the bolts can be reused during the bleeding procedure. After air bleeding is complete, replace the bolts with new ones.
    1. GTY1064117Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Brake Warning Light (Yellow) - -
      1. Perform the following procedure:
        1. Perform the procedure to enter rear disc brake pad replacement mode 5 times.

          Refer to REAR BRAKE PAD REPLACEMENT MODE [10/2022 - ]

        2. Remove the brake master cylinder reservoir filler cap assembly.
        3. Force air within the rear disc brake cylinder assembly to accumulate at the rear disc brake bleeder plug.(*1)
          1. Disable brake control.

            See step  4 [10/2022 - 08/2023], or see step  4 [08/2023 - ]

          2. Disconnect the No. 2 parking brake wire assembly connector.

            Refer to PROCEDURE - Step 4

          3. Hold the 2 rear disc brake cylinder slide pins and remove the 2 bolts and separate the rear disc brake cylinder assembly from the rear disc brake cylinder mounting.
          4. Hold the rear disc brake cylinder assembly horizontally, then tilt it 45° toward the bleeder plug side as shown in the illustration.
          5. Temporarily install the rear disc brake cylinder assembly to the rear disc brake cylinder mounting with the 2 bolts.
          6. Connect the No. 2 parking brake wire assembly connector.

            Refer to PROCEDURE - Step 3

          7. Connect the reservoir level switch connector.
          8. Connect the cable to the negative (-) auxiliary battery terminal.

            Refer to INSTALLATION [10/2022 - 08/2023] , or refer to INSTALLATION [08/2023 - ]

          9. Turn the ignition switch to ON (READY).
          10. Depress the brake pedal and release it.
          11. Apply the parking brake.
        4. Enter ECB (Electronically Controlled Brake system) Deactivate Mode.(*2)
          NOTE:
          • Performing the following procedure enters ECB (Electronically Controlled Brake system) Deactivate Mode without using the GTS.
          • ECB (Electronically Controlled Brake system) Deactivate Mode allows the brake lines to be bled without using the GTS.
          • The brake warning light blinks (yellow) to indicate that ECB (Electronically Controlled Brake system) Deactivate Mode is selected.
          • Be sure to confirm that the brake warning light is blinking (yellow) throughout the brake line bleeding procedure.
          • If any of the following conditions are met, ECB (Electronically Controlled Brake system) Deactivate Mode is canceled and the brake warning light (yellow) turns off. Do not allow ECB (Electronically Controlled Brake system) Deactivate Mode to be canceled while bleeding the brake lines or DTCs may be stored.
            A shift state other than park (P) is selected.
            The ignition switch is turned to ON (READY).
            The ignition switch is turned off.
            The parking brake is released.
            The vehicle speed is more than 0 km/h (0 mph).
          • Do not rotate any brake disc while ECB (Electronically Controlled Brake system) Deactivate Mode is selected.
          • Although the brake warning light (yellow) will blink and a buzzer will sound while performing brake line bleeding, this is not a malfunction.
          1. Perform the procedure listed below within 1 minute.
            1. Turn the ignition switch to ON with park (P) selected and parking brake applied.
            2. Select neutral (N) and then depress the brake pedal more than 8 times within 5 seconds.
            3. Push the P position switch and then depress the brake pedal more than 8 times within 5 seconds.
            4. Select neutral (N) and then depress the brake pedal more than 8 times within 5 seconds.
            5. Push the P position switch.
          2. Check that the brake warning light is blinking (yellow).
        5. Bleed the brake line.(*3)
          1. Remove the rear disc brake bleeder plug cap.
          2. Connect a vinyl tube to the rear disc brake bleeder plug.
          3. Add brake fluid to the reservoir until the fluid level is between the MAX and MIN lines on the brake fluid reservoir.(*a)
          4. Depress the brake pedal several times with approximately 1 second between each depression, and then loosen the bleeder plug with the pedal depressed.(*b)
          5. When brake fluid stops coming out, tighten the bleeder plug and then release the brake pedal for 1 second or more.(*c)

            HINT: 

            When the brake pedal is released, the piston inside the master cylinder may take longer than the brake pedal to return to its original position. Therefore, make sure to wait for 1 second or more between each depression of the brake pedal.

          6. Repeat steps (*a) through (*c) until there are no signs of air in the brake fluid.
          7. Release the parking brake.
        6. Repeat steps (*1) through (*3) 3 times.
          NOTE:

          If there is still air in the system after performing steps (*1) through (*3) 3 times, repeat the steps (*1) through (*3) until the air has been bled.

        7. Tighten the rear disc brake bleeder plug completely.

          Torque

          8.3 N.m (85 kgf/cm, 73 in.lbf)

        8. Install the rear disc brake bleeder plug cap to the rear disc brake bleeder plug.
        9. Hold the 2 rear disc brake cylinder slide pins, and install the rear disc brake cylinder assembly to the rear disc brake cylinder mounting with 2 new bolts.

          Torque

          34.3 N.m (350 kgf/cm, 25 ft.lbf)

        10. Inspect for brake fluid leaks.
        11. Adjust the brake fluid level in the reservoir.

          Refer to ON-VEHICLE INSPECTION [10/2022 - ]

        12. Install the brake master cylinder reservoir filler cap assembly.
        13. Turn the ignition switch off.
        14. Clear the DTCs.

          Refer to DTC CHECK / CLEAR [10/2022 - ]

  18. INSTALL REAR WHEEL 

    Refer to INSTALLATION [10/2022 - ]

  19. NORMAL CONDITION RECOVERY 

    Refer to REAR BRAKE PAD REPLACEMENT MODE [10/2022 - ]

  20. INITIALIZATION AFTER RECONNECTING AUXILIARY BATTERY TERMINAL 

    Refer to WORK PROCEDURE [10/2022 - ]

    HINT: 

    When disconnecting and reconnecting the auxiliary battery, there is an automatic learning function that completes learning when the respective system is used.

    Refer to AUTOMATIC LEARNING CHART [10/2022 - 08/2023] , or refer to AUTOMATIC LEARNING CHART [08/2023 - ]

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