Restoring a 30-Year-Old Lexus LS400: Suspension, Brakes, and Final Touches

Engine and Initial Checks

• 🚗 The Lexus LS400 restoration reaches its final episode, with the engine running exceptionally smooth, almost vibration-free, even when warm.
• ⚠️ A small vacuum leak was identified due to a faulty hose, which is being addressed with a better replacement.
• 💡 The engine air filter was replaced with a rare, original Lexus part to maintain originality.
• ✅ All fluids have been filled, and the engine, transmission, and power steering are ready.

Rear Suspension and Knuckle Replacement

• 🛠️ The rear suspension work was challenging, particularly pressing in new bushings, which required improvisation due to a lack of specialized tools.
• 📦 Two brand new, old-stock knuckles were sourced, though they had minor surface rust.
• ⚠️ The control arms were replaced, with one arm needing replacement due to a height sensor mounting difference in newer parts.
• ⚙️ Bushings were pressed in and are holding, but long-term performance under load is yet to be fully confirmed.

Front Suspension and Brake Overhaul

• 🔧 The front suspension work involved replacing control arms, ball joints, shocks, and upper control arms.
• 🔩 Notorious strut rod bushings, a common failure point on LS400s causing clunking during braking or acceleration, were replaced.
• 🛑 Brake pads and rotors were worn out and replaced, with the rotor screws surprisingly coming out easily.
• ⚠️ The speed sensor was removed, and the knuckle was taken out for easier access to suspension components.
• 🔨 Ball joints were replaced due to noticeable side-to-side movement.
• 💥 The strut replacement involved significant spring compression, highlighting the danger and difficulty of this task.

Final Assembly and Test Drive

• 🏁 The sway bar bushings were also replaced during the suspension work.
• 🔧 New brake hoses were installed due to dry rot, ensuring safety and preventing future issues.
• 🚦 The car required multiple alignments due to an eccentric bolt issue, and adjustments were made to the steering rack.
• ✨ After extensive testing and addressing minor issues like a door lock, the LS400 drives beautifully, showcasing its over-engineered and smooth performance.
• 👍 The restoration successfully brought the rust-free, nearly 30-year-old car back to excellent driving condition, preserving its value and longevity.