IS 250/350 Conv (REAR)

IS 250/350 Conv (REAR)
LEXUS
IS 250/350
2006-2012
GS 350
2008-2011
IS 250/350 Conv (FRONT) 2010IS 250/350 Conv (REAR) 2010-2013
PERFORMANCE
BRAKE KIT
Preparation
Part Number:
PTR09-53108: All IS 250 Models - Front
PTR09-30102: IS 350 & GS 350 - Front
PTR09-53109: IS 250 AWD & RWD - Rear
PTR09-53110: All IS 350 Models - Rear
PTR09-53103: IS 250 C & GS 350 - Rear
PTR09-30101: GS 350 Fit Kit
Front Kit Contents
Item #
1
2
3
Quantity Reqd.
1
1
1
4
1
5
1
6
1
7
1
Description
Brake Rotor, LH Front
Brake Rotor, RH Front
Brake Caliper Assembly, LH
Front with Brake Pads
Brake Caliper Assembly, RH
Front with Brake Pads
Brake Caliper Bracket, LH
Front with M12 Washers &
7/16-20 Self-Locking Nuts
Brake Caliper Bracket, RH
Front with M12 Washers &
7/16-20 Self-Locking Nuts
Hardware Bag
Front Rotors
LH
LH
Outside
Outside Face Shown
TOP
RH
RH
Outside
TOP
LH
RH
Front Kit Hardware Contents
Item #
1
2
Quantity Reqd.
5*
2
3
2
4
5
6
7
8
1
1
1
1
1
Description
Copper Crush Washers
AWD Shims for Front Axle
Hubs (IS 250 Kits Only)
2WD Shims for Front Axle
Hubs
Spare Tire Warning Label
Installation Instructions
Mirror Hanging Tag
Brake Caliper Template
Owner’s Document
* 4 Required + 1 spare
AWD Shims
IS 250 Only
2WD Shims
Front
Calipers
Vehicle Service Parts (may be required for reassembly)
Item #
1
Issue: E 10/06/2015
Page 1 of 30 pages
Quantity Reqd.
2
Description
Front Axle Hub Nut , P/N
90177-22001 (for AWD only)
LEXUS
IS 250/350
2006-2012
GS 350
2008-2011
IS 250/350 Conv (FRONT) 2010IS 250/350 Conv (REAR) 2010-2013
PERFORMANCE
BRAKE KIT
Preparation
Rear Kit Contents
Item #
1
2
3
Rear Hardware Contents
Quantity Reqd.
1
1
1
4
1
5
2
6
1
Description
Brake Rotor, LH Rear
Brake Rotor, RH Rear
Brake Caliper Assembly, LH
Rear with Brake Pads
Brake Caliper Assembly, RH
Rear with Brake Pads
Brake Caliper Bracket, Rear
with M12 Washers & 7/16-20
Self-Locking Nuts
Hardware Bag
Rear Rotors
Item #
1
2
3
4
5
6
Quantity Reqd.
5*
1
1
1
1
1
Description
Copper Crush Washers
Spare Tire Warning Label
Installation Instructions
Mirror Hanging Tag
Brake Caliper Template
Owner’s Document
* 4 Required + 1 spare
GS Fit Kit Contents
Item #
1
Quantity Reqd.
2
2
1
3
1
Description
AWD Shims for Front Axle
Hubs
Rotor Spacer for trimming rear
dust shields
Installation Instructions
AWD Shims
LH
LH
Outside
Outside Face Shown
TOP
RH
RH
Outside
93.3 mm
Trimming
Spacer
Rear
Calipers
Additional Items Required For Installation
Item #
1
Issue: E 10/06/2015
Page 2 of 30 pages
Quantity Reqd.
Description
LEXUS
IS 250/350
2006-2012
GS 350
2008-2011
IS 250/350 Conv (FRONT) 2010IS 250/350 Conv (REAR) 2010-2013
PERFORMANCE
BRAKE KIT
Preparation
Recommended Tools
Personal & Vehicle
Protection
Conflicts
Notes
Safety Glasses
Vehicle Protection
Fender Covers
Work Gloves
Safety Glasses /face shield
Seat & Floor Covers
Special Tools
Notes
SST: 09930-00010
Chassis Lift or
Drive Shaft Nut Chisel
(Hydraulic Jack & Jack
Stands)
One per side
Fluid Drip Trays
TRD Brake Bleeding
Machine with IS/GS
Adaptor
Installation Tools
Notes
21mm Deep Socket
Air Impact Gun
10mm Combination Wrench
10mm Nut Driver
17mm Deep Socket
30mm Deep 12 point Socket
Torque Wrenches
½” Socket
14mm Socket
Air Powered Nibbler
Air Powered Cut Off Wheel
Air Powered Buffer Wheel
Hammer
Soft Mallet
11mm Combination Wrench
5mm Allen T-Wrench
Breaker Bar
Brush or Vacuum for Chips
11mm Deep Socket
½” Drive
½” Drive
½” Drive
½” Drive (AWD only)
3/8” & ½” Drive
3/8” Drive
3/8” Drive
General Applicability
Front & Rear Brake Upgrade can be installed on all IS 250
– 350 models except for vehicles with 17 in. OE Wheels.
Some OE 18 in. wheels may require the balance weights to
be placed behind the spokes as noted in the instructions.
Item #
1
2
3
4
5
Legend
3/8” Drive
Notes
#00475-1BF03 or Fluid:
SAE J1703 or FMVSS No.
116 DOT3
#00289-2BC00-CA
P/N 04002 purchased from
1-888-396-3848 or
www.markingpendepot.com
Accessory
Accessory Wheels/Tires *
Springs/Shocks
Sway Bars
Front Brake Upgrade
Rear Brake Upgrade
*Mandatory
½” Drive
Toyota Brake Fluid
Issue: E 10/06/2015
NOTE: The OE 18 in. wheels may need to be rebalanced
with the weights placed behind the wheel spokes to provide
required clearance.
Recommended Sequence of Application
Special Chemicals
Toyota Brake Cleaner
Black Felt Tip Paint Marker
17 in. OE Wheels will not fit. No conflicts with 18 in. OE,
Lexus Genuine Accessory and F-Sport Wheels except for
the IS Convertible. OE 18 in. wheels on the IS Convertible
do NOT provide sufficient clearance for F-Sport front
Performance Brake Kits. Lexus Genuine Accessory or FSport wheels are recommended.
Page 3 of 30 pages
STOP: Damage to the vehicle may occur. Do not
proceed until process has been complied with.
OPERATOR SAFETY: Use caution to avoid risk of
injury.
CAUTION: A process that must be carefully observed
in order to reduce the risk of damage to the
accessory/vehicle and to ensure a quality installation.
TOOLS & EQUIPMENT: Used in Figures calls out the
specific tools and equipment recommended for this
process.
REVISION MARK: This mark highlights a change in
installation with respect to previous issue.
SAFETY TORQUE: This mark indicates that torque is
related to safety.
LEXUS
IS 250/350
2006-2012
GS 350
2008-2011
IS 250/350 Conv (FRONT) 2010IS 250/350 Conv (REAR) 2010-2013
PERFORMANCE
BRAKE KIT
Preparation
Care must be taken when installing this accessory to ensure damage does not occur to the vehicle. The installation of this
accessory should follow approved guidelines to ensure a quality installation.
These guidelines can be found in the "Accessory Installation Practices" document.
This document covers such items as:
Vehicle Protection (use of covers and blankets, cleaning chemicals, etc.).

Safety (eye protection, rechecking torque procedure, etc.).

Vehicle Disassembly/Reassembly (panel removal, part storage, etc.).

Electrical Component Disassembly/Reassembly (battery disconnection, connector removal, etc.).
Please see your Lexus dealer for a copy of this document.
1. Prepare the Vehicle.
(a) Before working on the vehicle, protect the
seats and carpets with covers. Open the hood
and place a Fender Cover over the driver side
fender to protect the vehicle paint.
2. Check the Kit Contents.
(a) Check the Front & Rear Brake Upgrade kits
for contents and damage.
NOTE: Because IS & GS Calipers look
identical, but differ with the internal piston
diameters, it is important to not open and prestage kits in a manner that might allow the
calipers to be mixed up. Attachment “C”
provides instructions on how to identify
calipers.
Issue: E 10/06/2015
Page 4 of 30 pages
LEXUS
IS 250/350
2006-2012
GS 350
2008-2011
IS 250/350 Conv (FRONT) 2010IS 250/350 Conv (REAR) 2010-2013
PERFORMANCE
BRAKE KIT
Procedure
3. Remove the Engine Room Side Cover.
(a) Remove the Engine Room LH Side cover by
removing six (6) push to release clips and
one 10mm plastic hex nut (Fig. 3-1). GS
vehicles have fewer clips.
Plastic Nut (1)
Push to Release
Clips (6)
Fig.3-1
4. Attach Brake Fluid Adaptor
Main Body
Base Ring
Knobs
(a) Remove brake reservoir cap.
(b) The brake fluid adaptor has the
components shown (Fig. 4-1). The parts
include the main body, the base ring, and
two knobs.
Fig.4-1
Issue: E 10/06/2015
Page 5 of 30 pages
LEXUS
IS 250/350
2006-2012
GS 350
2008-2011
IS 250/350 Conv (FRONT) 2010IS 250/350 Conv (REAR) 2010-2013
PERFORMANCE
BRAKE KIT
Procedure
Groove
(c) Fix the adaptor base in place by clamping
it around the lip at the top of the brake
fluid reservoir neck (Fig. 4-2 & 4-3). The
lip on top of the fluid reservoir fits in the
groove on the inside of the adaptor base.
Lightly tighten the 2 knobs but leave them
slightly loose so the base can rotate.
Lip
Fig.4-2
Fig.4-3
(d) Seat the o-ring on the bottom of the
adaptor in the top of the reservoir neck and
attach the 2 long clamps (Fig. 4-4). Snug
all 4 knobs finger tight. It helps to twist the
adaptor while pushing down making it
easier to get the o-ring into the reservoir
neck.
Fig 4-4
Issue: E 10/06/2015
Page 6 of 30 pages
LEXUS
IS 250/350
2006-2012
GS 350
2008-2011
IS 250/350 Conv (FRONT) 2010IS 250/350 Conv (REAR) 2010-2013
PERFORMANCE
BRAKE KIT
Procedure
(e) Attach the vacuum line to the adaptor as
shown in (Figs. 4-5 & 4-6).
Pressure
Line
Vacuum
Line
Bleeder Vacuum
Tubes
Fig. 4-5
Vacuum Line
(f) Close the air valve on the adaptor by
turning it clockwise as shown in (Fig. 4-6).
Air Valve
Fig. 4-6
(g) After making certain the brake fluid
reservoir on the brake bleeding machine is
full, press the B-1 Button on the brake
bleeding machine control panel as shown
in (Fig. 4-7). After 50 seconds, an alarm
will sound. Press STOP on the control
panel to quiet the alarm.
Fig. 4-7
Issue: E 10/06/2015
NOTE: You may continue to the next step
while waiting for the alarm to sound.
Page 7 of 30 pages
LEXUS
IS 250/350
2006-2012
GS 350
2008-2011
IS 250/350 Conv (FRONT) 2010IS 250/350 Conv (REAR) 2010-2013
PERFORMANCE
BRAKE KIT
Procedure
5. Remove the Front Wheels.
(a) Use a vehicle hoist to lift the vehicle using
the vehicle jacking points. If a vehicle hoist
is not available, use a hydraulic jack to lift
the front of the vehicle and set it on jack
stands. Use the owner’s manual to locate the
proper vehicle jacking points.
CAUTION: Always use jack stands to support
the vehicle, never work on a vehicle using only
the jack.
(b) Use a 21mm deep socket and ½” air impact
gun to remove all wheel lug nuts. If wheel
locks are installed, they must be removed
by hand.
(c) Remove all four wheel/tire assemblies and
save for reuse.
(d) Place drip trays under each caliper assembly
to catch any brake fluid that may drip in
subsequent steps.
6. Disconnect the Front Speed Sensor.
For 2WD go to Step 6(a), for AWD go to 6(b)
(a) Disconnect the speed sensor connector from
the front speed sensor (Fig 6-1).
CAUTION: Prevent foreign matter from
adhering to the speed sensor.
Fig. 6-1
Issue: E 10/06/2015
Page 8 of 30 pages
LEXUS
IS 250/350
2006-2012
GS 350
2008-2011
IS 250/350 Conv (FRONT) 2010IS 250/350 Conv (REAR) 2010-2013
PERFORMANCE
BRAKE KIT
Procedure
(b) Remove the 2 bolts and separate the speed
sensor from the steering knuckle (Fig. 6-2).
CAUTION: Be careful not to damage the
speed sensor. Prevent foreign matter from
adhering to the speed sensor.
7. Remove Factory Front Brake Caliper &
Rotor.
Fig. 6-2
7(a)
7(b)
7(b)
Fig. 7-1
(a) Loosen and then remove the union bolt from
the OE brake caliper that secures the flexible
hose to the caliper. Remove and discard the
aluminum gasket from the end of the flexible
hose (Fig. 7-1).
(b) Remove the 2 bolts and disconnect the brake
caliper Assembly (Fig. 7-1). Retain these
bolts, but discard the caliper.
(c) Remove and discard the brake rotor (also
called disk).
8. Replace the Dust Cover with Shims.
For 2WD go to Step 8(a), for AWD go to 8(c)
(a) Remove the 4 bolts, front axle hub subassembly and dust cover (Fig.8-1). Discard
the dust cover.
Fig. 8-1
(b) Reinstall the front axle hub assembly to the
steering knuckle using the 2WD shim in
place of the dust cover between the steering
knuckle and the front axle hub assembly.
Tighten the 4 bolts.
Torque: 51 lbf·ft (69 N·m).
Issue: E 10/06/2015
Page 9 of 30 pages
LEXUS
IS 250/350
2006-2012
GS 350
2008-2011
IS 250/350 Conv (FRONT) 2010IS 250/350 Conv (REAR) 2010-2013
PERFORMANCE
BRAKE KIT
Procedure
For 2WD go to Step 9
(c) Using SST and a hammer, release the staked
part of the front axle hub nut (Fig. 8-2).
Remove and discard the nut as it is to be
replaced with a new nut, P/N 90177-22001.
SST: 09930-00010
Fig. 8-2
CAUTION: Release the staked portion of the
nut completely; otherwise the threads on the
drive shaft may be damaged.
(d) Using a plastic hammer, separate the front
drive shaft assembly from the front axle hub.
CAUTION: Be careful not to damage the
front drive shaft boot.
(e) Remove the 4 bolts, front axle hub subassembly (Fig 8-3) and dust shield. Retain
the bolts and axle sub-assembly. Discard the
dust cover.
Fig. 8-3
(f) Reinstall the front axle hub assembly to the
front drive shaft assembly and the steering
knuckle using the 4WD shims in place of the
dust covers between the steering knuckle and
the front axle hub assembly. Tighten the 4
bolts.
Torque: 51 lbf·ft (69 N·m)
CAUTION: Be careful not to damage the
front drive shaft boot.
(g) Install a new front axle hub nut using a 30
mm socket and snug it in place. It will not be
torqued until after the brakes have been bled.
Issue: E 10/06/2015
Page 10 of 30 pages
LEXUS
IS 250/350
2006-2012
GS 350
2008-2011
IS 250/350 Conv (FRONT) 2010IS 250/350 Conv (REAR) 2010-2013
PERFORMANCE
BRAKE KIT
Procedure
(h) Reinstall the speed sensor (Fig. 6-2). Torque
the upper bolt to 120 lbf·in (14 N·m) and the
lower bolt to 75 lbf·in (8.5 N·m).
Torque Upper: 120 lbf·in (14 N·m)
Torque Lower: 75 lbf·in (8.5 N·m)
9. Install the F-Sport Front Rotor & Caliper.
(a) Install the caliper bracket to the steering
knuckle using the original caliper mounting
bolts removed earlier (Fig 9-1).
Torque: 58 lbf·ft (78 N·m)
Fig. 9-1
(b) Make certain the hub face and the centering
ring on the hub are free of excess rust and or
dirt.
(c) Install the rotor assembly, seating it squarely
on the hub face. Place two wheel nuts on
opposite studs to prevent the rotor from
falling off the hub and to hold it in place
(finger tight) (Fig. 9-2).
Fig. 9-2
CAUTION: The rotor hats have a small L
(left) or R (right) sticker. Install “L” on the
left side and “R” on the right side.
(d) Once the rotor is in place, remove the “L” or
“R” sticker and clean any adhesive residue.
Issue: E 10/06/2015
Page 11 of 30 pages
LEXUS
IS 250/350
2006-2012
GS 350
2008-2011
IS 250/350 Conv (FRONT) 2010IS 250/350 Conv (REAR) 2010-2013
PERFORMANCE
BRAKE KIT
Procedure
(e) With the caliper on a padded work bench,
using an M5 Allen wrench back out the 2
outer bridge bolts 3 turns (Fig 9-3). Then
turn the caliper over and remove the foam
insert from between the brake pads.
Fig. 9-3
Bleed Screws
go up
Fig. 9-4
Bracket
Studs
(f) After removing the nuts and washers from
the caliper bracket studs, install the
caliper/pad assembly onto the rotor with the
bleed screws up while aligning the mounting
holes with the studs (Fig. 9-4). Install the
washers and then the nuts. Tighten the nuts.
Torque: 40 lbf·ft (54 N·m).
CAUTION: The calipers have a small L (left)
or R (right) sticker. Install “L” on the left side
and “R” on the right side.
(g) Once the caliper is in place, remove the “L”
or “R” sticker and clean any adhesive
residue.
(h) Re-tighten the 2 outer bridge bolts on the
caliper until snug using an M5 Allen Twrench. Do not use a torque wrench, the antiseize compound will cause a false reading.
Do not over-torque these bolts, snug is tight
enough.
Issue: E 10/06/2015
Page 12 of 30 pages
LEXUS
IS 250/350
2006-2012
GS 350
2008-2011
IS 250/350 Conv (FRONT) 2010IS 250/350 Conv (REAR) 2010-2013
PERFORMANCE
BRAKE KIT
Procedure
10. Attach the Original Front Flexible Brake
Hose.
NOTE: Inspect both sides of the copper
washers used in the following step to ensure
they are flat & smooth. One spare washer is
included in the kit in case of loss or damage.
Anti-Rotation
Tang
Copper
Washers
(a) Using two copper washers, one on each side
of the banjo fitting on the end of the flexible
brake hose, re-insert the union bolt through
the banjo fitting and screw it into the caliper
(Fig. 10-1). Note how the anti-rotation tang
on the banjo fitting fits in the slot on the
caliper.
Slot
Fig. 10-1
Torque: 14 lbf·ft (19 N·m)
CAUTION: Make sure the original aluminum
gasket has first been removed from the banjo
fitting. Do not over tighten the banjo bolt.
Doing so can strip the aluminum threads in
the caliper, causing irreparable damage to the
caliper. Also, make sure that the flexible hose
is not twisted when it is installed on the new
caliper. Immediately clean any spilled fluid.
(b) Have an assistant turn the steering wheel
while observing the flexible brake hose for
any binding. Also check for clearance to all
suspension components.
Repeat Steps 6(a) through 10(b) for the
opposite side of the vehicle.
Issue: E 10/06/2015
Page 13 of 30 pages
LEXUS
IS 250/350
2006-2012
GS 350
2008-2011
IS 250/350 Conv (FRONT) 2010IS 250/350 Conv (REAR) 2010-2013
PERFORMANCE
BRAKE KIT
Procedure
11. Remove Factory Rear Brake Caliper.
Brake
Line
Bolt
Brake
Caliper
Bolts
(a) Loosen and remove the union bolt holding
the brake line flexible hose to the caliper.
Remove and discard the aluminum gasket
from the end of the flexible hose (Fig. 11-1).
Fig. 11-1
(b) Remove the 2 bolts and discard the brake
caliper assembly (Figs. 11-1 & 11-2). Retain
the 2 bolts. Leave the factory rear rotors in
place.
12. Trim the Rear Dust Cover.
Fig. 11-2
CAUTION: This section must NOT be
omitted.
NOTE: The dust cover must be trimmed in
order for the new rotor and caliper to fit &
function properly.
For the all IS models C, go to Step 12(a)
For the GS 350, go to Step 12(b)
(a) Install 2 lug nuts finger tight to hold the
original rear brake rotor in place.
Issue: E 10/06/2015
Page 14 of 30 pages
LEXUS
IS 250/350
2006-2012
GS 350
2008-2011
IS 250/350 Conv (FRONT) 2010IS 250/350 Conv (REAR) 2010-2013
PERFORMANCE
BRAKE KIT
Procedure
For the all IS models, go to Step 12(d)
(b) Remove the rotor and install the orange
spacers (Figs. 12-1 & 12-2). The spacer
snaps into the two M8 threaded holes.
(c) Install 2 lug nuts finger tight to hold the
original rear brake rotor in place with the
orange spacer inside.
Fig. 12-1
For the GS 350, go to Step 12(d)
Fig. 12-2
Issue: E 10/06/2015
Page 15 of 30 pages
LEXUS
IS 250/350
2006-2012
GS 350
2008-2011
IS 250/350 Conv (FRONT) 2010IS 250/350 Conv (REAR) 2010-2013
PERFORMANCE
BRAKE KIT
Procedure
Start Cut
Here
(d) Use an Air Powered Nibbler to start cutting
the dust cover at the top just above the
factory caliper opening as shown. Use the
outer edge of the brake rotor as a guide for
the nibbler (Figs. 12-3 & 12-4).
Rotor not
Shown
Fig. 12-3
Fig. 12-4
Start Cut
Here
(e) Continue cutting off the top portion of the
dust cover with nibbler as shown (Fig. 12-5).
Continue
Cut with
Nibbler
NOTE: Rotor disk is not shown for clarity.
Fig. 12-5
Continue
Cut with
Nibbler
(f) Continue cut with nibbler around down to
bottom section as shown (Fig. 12-6).
NOTE: Rotor disk is not shown for clarity.
Final Cut
with Cutting
Wheel
Fig. 12-6
Issue: E 10/06/2015
Page 16 of 30 pages
LEXUS
IS 250/350
2006-2012
GS 350
2008-2011
IS 250/350 Conv (FRONT) 2010IS 250/350 Conv (REAR) 2010-2013
PERFORMANCE
BRAKE KIT
Procedure
(g) Remove and discard the brake rotor/disc.
NOTE: Before discarding the brake rotor,
remove and save the rubber plug from the
parking brake adjustment access hole and the
orange spacer used on the GS.
(h) Complete the cut by cutting the final lower
section of the dust cover with a small cutting
wheel as shown (Figs. 12-6 & 12-7).
Fig. 12-7
Complete
Cut with
Cutting
Wheel
(i) Temporarily install the caliper bracket using
the original caliper mounting bolts removed
earlier (Fig. 12-8).
Caliper
Bracket
Cut off this
section
Fig. 12-8
TOP
Cut off this
section
Fig. 12-9
Issue: E 10/06/2015
Cut off this
section
BOTTOM
(j) Mark the top portion of the dust cover to be
cut to allow the caliper to fit properly as
shown (Figs. 12-8 & 12-9).
(k) Mark the bottom portion of the dust cover to
be cut to allow the caliper to fit properly as
shown (Figs. 12-8 & 12-9).
(l) Remove the caliper bracket and cut off both
the top and bottom corners of the dust cover
as shown.
Page 17 of 30 pages
LEXUS
IS 250/350
2006-2012
GS 350
2008-2011
IS 250/350 Conv (FRONT) 2010IS 250/350 Conv (REAR) 2010-2013
PERFORMANCE
BRAKE KIT
Procedure
Fig. 12-10
(m) Use a power sander to smooth out all rough
edges along the cut lines of the dust cover
(Fig. 12-10). Once complete, brush or
vacuum all chips off the rear parking brake
assembly.
CAUTION: Make sure there are no rough
edges along the cut lines.
(n) Use the black paint felt tip marker to apply
black paint to all cut edges of the dust cover.
13. Install the F-Sport Rotor & Caliper.
(a) Install the caliper bracket to the axle carrier
assy. using the original caliper mounting
bolts removed earlier (Fig 13-1).
Torque: 58 lbf·ft (78 N·m)
Fig. 13-1
(b) Make certain the hub face and the centering
ring on the hub are free of excess rust and or
dirt.
(c) Install the rotor assembly, seating it squarely
on the hub face. Place two wheel nuts on
opposite studs to prevent the rotor from
falling off the hub and to hold it in place
(finger tight) (Fig. 13-2).
Fig. 13-2
NOTE: The rotor hats have a small L (left) or
R (right) sticker. Install “L” on the left side
and “R” on the right side.
(d) Once the rotor is in place, remove the “L” or
“R” sticker and clean off any adhesive
residue.
Issue: E 10/06/2015
Page 18 of 30 pages
LEXUS
IS 250/350
2006-2012
GS 350
2008-2011
IS 250/350 Conv (FRONT) 2010IS 250/350 Conv (REAR) 2010-2013
PERFORMANCE
BRAKE KIT
Procedure
(e) Before installing the caliper remove the foam
insert from between the brake pads.
Bracket
Studs
Fig. 13-3
Bleed Screws
go up
(f) After removing the nuts and washers from
the caliper bracket studs, install the
caliper/pad assembly onto the rotor with the
bleed screws up by aligning the mounting
holes with the studs (Fig. 13-3 & 13-4).
Install the washers and then the nuts. Tighten
the ½” nuts.
Torque: 40 lbf·ft (54 N·m).
CAUTION: The calipers have a small L (left)
or R (right) sticker. Install “L” on the left side
and “R” on the right side.
(g) Once the caliper is in place, remove the “L”
or “R” sticker and clean any adhesive
residue.
Fig. 13-4
Issue: E 10/06/2015
Page 19 of 30 pages
LEXUS
IS 250/350
2006-2012
GS 350
2008-2011
IS 250/350 Conv (FRONT) 2010IS 250/350 Conv (REAR) 2010-2013
PERFORMANCE
BRAKE KIT
Procedure
14. Attach the Original Rear Flexible Brake
Hose.
NOTE: Inspect both sides of the copper
washers used in the following step to ensure
they are flat & smooth. One spare washer is
included in the kit incase of loss or damage.
Anti-Rotation
Tang
Slot
Copper
Washers
(a) Using two supplied copper washers, one on
each side of the banjo fitting, re-insert the
union bolt through the banjo fitting and
screw it into the caliper (Fig. 14-1). Note
how the anti-rotation tang on the banjo fitting
fits in the slot on the caliper.
Torque: 168 lbf·in (19 N·m)
Fig. 14-1
CAUTION: Make sure the original aluminum
gasket has first been removed from the banjo
fitting. Do not over tighten the banjo bolt.
Doing so can strip the aluminum threads in
the caliper, causing irreparable damage to the
caliper. Also, make sure that the flexible hose
is not twisted when it is installed on the new
caliper. Immediately clean any spilled fluid.
Repeat Steps 11(a) through 14(a) for the
opposite side of the vehicle.
Issue: E 10/06/2015
Page 20 of 30 pages
LEXUS
IS 250/350
2006-2012
GS 350
2008-2011
IS 250/350 Conv (FRONT) 2010IS 250/350 Conv (REAR) 2010-2013
PERFORMANCE
BRAKE KIT
Procedure
15. Attach Brake Bleeder Machine Pressure Line
(a) Lower the vehicle to gain access to the brake
fluid fill adaptor.
Pressure Line
Air Valve
(b) Disconnect the vacuum line and attach the
pressure line as shown in Fig. 15-1.
(c) Open the air bleed valve by turning
counterclockwise.
16. Bleed Brakes, all four corners of the vehicle.
Fig. 15-1
(a) Raise the vehicle.
(b) Attach one of the four bleeder vacuum tubes
to the outside bleeder screw on the Passenger
side rear caliper as shown in (Fig. 16-1).
Leave the remaining three vacuum tubes
open and unused in the bleeder machine.
HINT: The rear line is longer and may be
easier to use.
Fig. 16-1
(c) Press the B-3 Button on the bleeder machine
control panel.
(d) Open the bleeder screw ¼ turn.
NOTE: Tap the calipers with a soft mallet to
dislodge any trapped air bubbles. If you do
not see fluid in the clear tubing, confirm the
bleeder screws are open.
(e) Close the bleeder screw when you no longer
see any bubbles.
(f) Using the same vacuum line, bleed the
inboard bleeder screw on the passenger side
caliper. Once again, tap the caliper to help
remove air bubbles while bleeding.
Issue: E 10/06/2015
Page 21 of 30 pages
LEXUS
IS 250/350
2006-2012
GS 350
2008-2011
IS 250/350 Conv (FRONT) 2010IS 250/350 Conv (REAR) 2010-2013
PERFORMANCE
BRAKE KIT
Procedure
(g) Continue to the driver side rear caliper and
bleed the outside bleeder screw followed by
the inside.
(h) Again tap both calipers and then repeat Steps
16(d) through 16(g).
(i) Bleeding is complete when a solid stream of
brake fluid free of bubbles is observed from
all four bleeder screws on the second
sequence of bleeding. Tighten the bleeder
screws.
Torque 120 lbf·in (13 N·m)
Repeat Steps 16(b) through 16(i) for the front
calipers starting on the outside of the
passenger side caliper.
(j) Press the STOP button on the control panel
once all four calipers have been bled.
(k) Hold a rag to wipe any dripping brake fluid
while removing the four bleeder vacuum
tubes.
Issue: E 10/06/2015
Page 22 of 30 pages
LEXUS
IS 250/350
2006-2012
GS 350
2008-2011
IS 250/350 Conv (FRONT) 2010IS 250/350 Conv (REAR) 2010-2013
PERFORMANCE
BRAKE KIT
Procedure
17. Clean the Calipers.
Fig. 17-1
(a) Remove any traces of brake fluid which may
remain in the bleed screw nipples by
spraying brake cleaner into each one, and
using a soft cloth to wipe away any excess
(Fig. 17-1). Insert the tip of the plastic tube
down into the bleeder screws until it reaches
the bottom. While holding a rag tightly
around the bleeder screw, squirt a small
amount of brake cleaner into the bleeder
screw.
CAUTION: Failure to clean the brake fluid
from inside the bleed screw nipples will allow
brake fluid to seep past the threads and
discolor the caliper paint.
18. Check for Leaks.
(a) Have a second person depress brake pedal
slowly 3-4 times and hold brake pedal down.
Check for fluid leaks while the brake pedal is
depressed. Check the connections at the
banjo fitting ends of the brake hoses, and all
bleed screws.
(b) Cover all 8 bleed screws with the attached
rubber caps.
19. Torque & Stake Front Axle Nuts (AWD only)
(a) With an assistant holding the brake pedal,
torque and stake both front axle nuts.
Torque: 217 lbf·ft (294 N·m).
Issue: E 10/06/2015
Page 23 of 30 pages
LEXUS
IS 250/350
2006-2012
GS 350
2008-2011
IS 250/350 Conv (FRONT) 2010IS 250/350 Conv (REAR) 2010-2013
PERFORMANCE
BRAKE KIT
Procedure
20. Perform a Torque Audit
(a) Perform a Torque Audit on all
Measure Torque and Document
(All
fasteners)
fasteners.
(b) Record the torque values on the Torque
Audit Sheet (Fig 20-1).
Fig. 20-1
21. Reinstall the Wheels and Lower the Vehicle.
(a) Confirm the type of wheel on the vehicle. If
the OE 18 in. wheel for the IS 250 or IS 350
Sedan is used (Fig 21-1), follow the next
steps to re-balance the front wheels. All
other acceptable Lexus Sport, Lexus
Genuine Accessory or F-Sport wheels will
not require this step.
Fig. 21-1
Issue: E 10/06/2015
Page 24 of 30 pages
LEXUS
IS 250/350
2006-2012
GS 350
2008-2011
IS 250/350 Conv (FRONT) 2010IS 250/350 Conv (REAR) 2010-2013
PERFORMANCE
BRAKE KIT
Procedure
Remove weights
from this area
(b) Inspect wheel for weights located in the
concern area shown in (Fig. 21-2).
(1) If there are no weights found in this
location you can now mount the wheel.
Weights are
allowed in these
areas
Fig. 21-2
(2) If weight is found here remove and rebalance the wheel assy.
(c) Rebalance the wheel using the split spoke
feature on your tire balancing machine.
Back side of wheel
Weights split between spokes
Fig 21-3
(1) You may have to choose the gap between
the double spokes as a spoke selection
point for your tire balancing machine.
(Fig. 21-3).
(2) If your tire balancer does not have this
feature, you will have to use your best
judgment to split the weight added
behind the spokes.
CAUTION: There must be at least a 3.5 mm
gap between the wheel weights and brake
caliper.
(3) Apply weights as shown (Figs. 21-2 &
21-3).
(a) Remove dirt, oil and water from the
surface where the balance weight is to
be adhered.
(b) Do not touch the sticking surface of
the tape.
(c) Adhere the sticking type balance
weight to the flat position shown in
the illustration.
Issue: E 10/06/2015
Page 25 of 30 pages
LEXUS
IS 250/350
2006-2012
GS 350
2008-2011
IS 250/350 Conv (FRONT) 2010IS 250/350 Conv (REAR) 2010-2013
PERFORMANCE
BRAKE KIT
Procedure
(d) Push the balance weight securely
with a finger to adhere it behind the
spokes.
(e) Do not reuse a balance weight.
(d) Reinstall the wheels. Tighten the lug nuts
hand tight.
CAUTION: Do not allow the wheel to bump
against the caliper or rotor and this can chip
the paint.
(e) Carefully rotate each wheel completely by
hand, checking for any excess resistance and
or interference.
(f) After initially snugging the lug nuts, lower
the vehicle until the tires just touch the
ground.
(g) Use a 21mm socket, splined key (if
necessary) and torque wrench to tighten the
lug nuts in sequence 1 through 5 (Fig. 21-4).
Torque 2 Cycles
(All Lugs/Locks)
Torque: 76 lbf·ft (103 Nm)
(h) Re-torque all lug nuts in same 1-5 sequence
(Fig 21-4).
Torque: 76 lbf·ft (103 Nm)
2x
CAUTION: DO NOT USE IMPACT
WRENCH TO INSTALL OR REMOVE
WHEEL LOCKS.
Fig. 21-4
Issue: E 10/06/2015
Page 26 of 30 pages
LEXUS
IS 250/350
2006-2012
GS 350
2008-2011
IS 250/350 Conv (FRONT) 2010IS 250/350 Conv (REAR) 2010-2013
PERFORMANCE
BRAKE KIT
Procedure
(i) With the vehicle still on the lift, use a digital
torque wrench to measure the torque of each
lug nut/lock and record it on the Torque
Audit Sheet (Fig. 21-5).
Measure Torque and Document
(All Lugs/Locks)
STOP
Fig. 21-5
Issue: E 10/06/2015
NOTE: Both wheels should not rotate when
the lug nuts are being torqued. If the wheels
rotate, then re-check for fluid leaks. If no
leaks are found, remove wheels and repeat
brake bleeding procedure.
(j) Lower vehicle from lift or jack stands and
apply brakes to ensure they are functioning
properly before driving vehicle away.
Page 27 of 30 pages
LEXUS
IS 250/350
2006-2012
GS 350
2008-2011
IS 250/350 Conv (FRONT) 2010IS 250/350 Conv (REAR) 2010-2013
PERFORMANCE
BRAKE KIT
Procedure
22. Place the Documents and Move the Vehicle.
(a) Place break-in procedure tag on inside
mirror, and owner’s document in glove box.
Fig. 22-1
(b) Attach the spare tire warning label to the
vehicle lug wrench as shown (Fig. 22-1).
Replace the lug wrench in its storage bag
(Fig. 22-2) and replace the storage bag in the
vehicle.
(c) Carefully move vehicle at low speed and
apply brakes gently several times to ensure
that all components are working correctly.
Warning: Do not drive vehicle and apply brakes
aggressively until rotors have been properly
bedded or broken-in.
Fig. 22-2
Issue: E 10/06/2015
Page 28 of 30 pages
LEXUS
IS 250/350
2006-2012
GS 350
2008-2011
IS 250/350 Conv (FRONT) 2010IS 250/350 Conv (REAR) 2010-2013
PERFORMANCE
BRAKE KIT
Procedure
Care and Maintenance
Issue: E 10/06/2015

Your brake calipers have a painted finish.
Immediately clean off any spilled brake fluid,
wiping it off with a soft, clean terry-cloth towel.
Rinse the area with clean water.

Bedding-in rotors and pads is critical to the
optimum performance of your new brakes.
When bedding-in new parts, you are not only
heat-cycling the pads, you are also depositing a
layer of pad material onto the rotor face. If not
bedded-in properly, an uneven layer of pad
material will be deposited onto the rotor, causing
vibration.

Wash F-Sport Performance Brake system and
wheels with mild soap and rinse with water.
Chemical-based wheel cleaners can permanently
discolor the anodized finish on the rotor hats.
More frequent wheel cleanings may be required
with less aggressive cleaning techniques.
Page 29 of 30 pages
LEXUS
IS 250/350
2006-2012
GS 350
2008-2011
IS 250/350 Conv (FRONT) 2010IS 250/350 Conv (REAR) 2010-2013
PERFORMANCE
BRAKE KIT
Checklist - these points MUST be checked to ensure a quality installation.
Check:
Accessory Function Checks
Look For:
Check for Leaks
There should be no brake fluid leaks at the
hose ends and bleeder screws.
Document Check
The TRD Big Brake Kit Mirror Tag should
be hanging from the vehicle mirror and the
TRD Big Brake Kit Owners Manual should
be in the vehicle glove box. The spare tire
warning label should be on the vehicle lug
wrench.
Torque Audit
All Delta-S Fasteners must be audited and
recorded on the applicable Torque Audit
Sheet.
Vehicle Function Checks
The vehicle brake fluid level should be full.
Brake Fluid Level
The vehicle brake pedal should be firm and
solid when depressed and held while the
engine is running.
Brake Pedal Feel
Vehicle Appearance Check
After accessory installation and removal of
protective cover(s), perform a visual
inspection.
Ensure no damage (including scuffs and
scratches) was caused during the
installation process.
(For PPO installations, refer to TMS
Accessory Quality Shipping Standard.)
Issue: E 10/06/2015
Page 30 of 30 pages
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