Lexus ES manuals

Lexus ES: Installation

Lexus ES (XZ10) Service Manual / Drivetrain / Axle And Differential / Front Axle Hub / Installation

INSTALLATION

CAUTION / NOTICE / HINT

for HV Model:

  • When removing or installing the front disc brake caliper assembly, pushing back the disc brake piston may cause a large clearance between the brake pads and brake disc. When the brake pedal is depressed with a large clearance between the brake pads and the brake disc, DTC C1214 related to abnormal brake fluid pressure may be stored. Make sure to clear any DTCs after performing this procedure.
  • While the auxiliary battery is connected, even if the power switch is off, the brake control system activates when the brake pedal is depressed or any door courtesy switch turns on. Therefore, when servicing the brake system components, do not operate the brake pedal or open/close the doors while the auxiliary battery is connected.

HINT:

  • Use the same procedure for the RH side and LH side.
  • The following procedure is for the LH side.

PROCEDURE

1. INSTALL FRONT AXLE HUB SUB-ASSEMBLY

(a) Secure the steering knuckle between aluminum plates in a vise.

NOTICE:

Do not overtighten the vise.

(b) Install the front axle hub sub-assembly and front disc brake dust cover to the steering knuckle with the 4 bolts.

Torque:

120 N·m {1224 kgf·cm, 89 ft·lbf}

NOTICE:

  • Be careful not to damage the speed sensor rotor or contact surfaces.
  • Do not allow foreign matter to contact the speed sensor rotor or contact surfaces.

2. INSTALL FRONT AXLE ASSEMBLY

(a) Apply 0.1 to 0.3 g (0.00353 to 0.0105 oz) of Toyota Body Grease W to each of the 4 areas shown in the illustration.

Toyota Body Grease W

(b) Install the front axle assembly to the front shock absorber assembly with the 2 bolts and 2 nuts.

Torque:

290 N·m {2957 kgf·cm, 214 ft·lbf}

NOTICE:

  • Do not apply lubricants to the steering knuckle and shock absorber contact surfaces.
  • When installing the nuts, keep the bolts from rotating.

HINT:

The bolts can be installed in either direction, however, make sure that they are both installed in the same direction.

3. INSTALL FRONT DRIVE SHAFT ASSEMBLY

(a) Align the matchmarks on the front drive shaft assembly and front axle hub sub-assembly, and connect the front drive shaft assembly to the front axle assembly.

NOTICE:

  • Do not push the front axle assembly towards the outside of the vehicle any further than necessary.
  • Check that there is no foreign matter on the speed sensor rotor or contact surfaces.
  • Do not damage the front drive shaft outboard joint boot.
  • Do not damage the front disc brake dust cover.
  • Do not damage the speed sensor rotor.

*a

Matchmark

4. CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY

(a) Connect the front lower No. 1 suspension arm sub-assembly to the front lower ball joint assembly with the bolt and 2 nuts.

Torque:

92 N·m {938 kgf·cm, 68 ft·lbf}

5. CONNECT TIE ROD ASSEMBLY

Click here

6. INSTALL FRONT DISC

Click here

7. INSTALL FRONT DISC BRAKE CALIPER ASSEMBLY

Click here

8. INSTALL FRONT AXLE SHAFT NUT

(a) Clean the threaded parts on the front drive shaft assembly and a new front axle shaft nut using non-residue solvent.

NOTICE:

  • Be sure to perform this work even when using a new front drive shaft assembly.
  • Keep the threaded parts free of oil and foreign matter.

(b) Using a 30 mm deep socket wrench, while applying the brakes, temporarily install the front axle shaft nut.

Torque:

294 N·m {2998 kgf·cm, 217 ft·lbf}

NOTICE:

Stake the front axle shaft nut after inspecting for looseness and runout in the following steps.

HINT:

Keep depressing the brake pedal to prevent the front drive shaft from rotating.

9. SEPARATE FRONT DISC BRAKE CALIPER ASSEMBLY

Click here

10. REMOVE FRONT DISC

Click here

11. INSPECT FRONT AXLE HUB BEARING LOOSENESS

Click here

12. INSPECT FRONT AXLE HUB RUNOUT

Click here

13. INSTALL FRONT DISC

Click here

14. INSTALL FRONT DISC BRAKE CALIPER ASSEMBLY

Click here

15. INSTALL FRONT SPEED SENSOR (w/o AVS)

(a) Engage the 2 hooks to install the front speed sensor clamp bracket.

Hook

NOTICE:

Do not twist the front speed sensor when installing it.

(b) Install the front speed sensor and front flexible hose to the front shock absorber assembly with the bolt.

Torque:

29 N·m {296 kgf·cm, 21 ft·lbf}

NOTICE:

Do not twist the front flexible hose when installing it.

(c) Install the front speed sensor to the steering knuckle with the bolt.

Torque:

8.5 N·m {87 kgf·cm, 75 in·lbf}

NOTICE:

  • Prevent foreign matter from attaching to the front speed sensor tip.
  • Firmly insert the front speed sensor body into the steering knuckle before tightening the bolt.
  • After installing the front speed sensor to the steering knuckle, make sure that there is no clearance between the front speed sensor stay and steering knuckle. Also make sure that no foreign matter is stuck between the parts.
  • Do not twist the front speed sensor when installing it.

(d) Engage the clamp.

NOTICE:

Do not twist the front speed sensor when installing it.

16. INSTALL FRONT SPEED SENSOR (w/ AVS)

(a) Engage the 2 hooks to install the front speed sensor clamp bracket.

Hook

NOTICE:

Do not twist the front speed sensor when installing it.

(b) Install the front speed sensor and front flexible hose to the front shock absorber assembly with the bolt.

Torque:

29 N·m {296 kgf·cm, 21 ft·lbf}

NOTICE:

Do not twist the front flexible hose when installing it.

(c) Install the front speed sensor to the front shock absorber assembly and steering knuckle with the 2 bolts.

Torque:

Bolt (A) :

8.5 N·m {87 kgf·cm, 75 in·lbf}

Bolt (B) :

29 N·m {296 kgf·cm, 21 ft·lbf}

NOTICE:

  • Prevent foreign matter from attaching to the front speed sensor tip.
  • Firmly insert the front speed sensor body into the steering knuckle before tightening the bolt.
  • After installing the front speed sensor to the steering knuckle, make sure that there is no clearance between the front speed sensor stay and steering knuckle. Also make sure that no foreign matter is stuck between the parts.
  • Do not twist the front speed sensor when installing it.

(d) Connect the AVS connector to the absorber control actuator.

17. STAKE FRONT AXLE SHAFT NUT

(a) Using a chisel and hammer, stake the front axle shaft nut.

18. INSTALL FRONT WHEEL

Click here

19. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL (for HV Model)

(a) Connect the reservoir level switch connector.

(b) Connect the cable to the negative (-) auxiliary battery terminal.

Click here

(c) Turn the power switch on (READY).

(d) Depress the brake pedal and release it.

(e) Clear the DTCs.

Click here

20. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

Click here

21. CHECK FOR SPEED SENSOR SIGNAL

for HV Model: Click here

for Gasoline Model: Click here

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