parking brake ISUZU TF SERIES 2004 User Guide

BRAKES 5C-29

ADJUSTMENT PROCEDURE OF SERVICE AND PARKING BRAKE




Stem type
All brakes are self-adjusting.
Brakes are adjusted by repeated stepping on the brake pedal.
(After stepping on the pedal and releasing it, the rear auto-
adjuster, in the rear brake, produces a clicking sound.
the same operation should be repeated until the sound
disappears.)
Take the following steps after overhauling the rear brake
assembly.
1. Move the parking brake lever to its fully released position.

311R300007





























































2. Parking cable must be loosened sufficiently.
(Loosen the adjust nut and the lock nut.)
3. Repeat stepping on the brake pedal firmly, and releasing i
t
until the clicking sound can no longer be heard.

If the difference between the brake drum inside diameter o
f
the brake shoes is adjusted to be 0.5 mm, the number o
f
times for depressing the brake pedal can be reduced.
4. Remove the drum.

Measure the brake drum inside diameter and diameter o
f
the brake shoes.
Shoe Clearance mm(in)
0.25 - 0.40 (0.0098 - 0.0157)
If incorrect, check the brake auto-adjusting system.
5. Turn the adjuster nut so that the parking brake lever travels
8 to 14 notches when pulled up with a force 30 kg (66 lbs.).
6. Make sure there is not brake dragging.



Floor mount type
All brakes are self-adjusting.
Brakes are adjusted by repeated stepping on the brake pedal.
(After stepping on the pedal and releasing it, the rear auto-
adjuster, in the rear brake, produces a clicking sound.
the same operation should be repeated until the sound
disappears.)
Take the following steps after overhauling the rear brake
assembly.
1. Move the parking brake lever to its fully released position.
2. Parking cable must be loosened sufficiently.
(Loosen the adjust nut and the lock nut.)
3. Repeat stepping on the brake pedal firmly, and releasing i
t
until the clicking sound can no longer be heard.

If the difference between the brake drum inside diameter o
f
the brake shoes is adjusted to be 0.5 mm, the number of
times for depressing the brake pedal can be reduced.
4. Remove the drum.

Measure the brake drum inside diameter and diameter o
f
the brake shoes.

5C-30 BRAKES

Shoe Clearance mm(in)
0.25 - 0.40 (0.0098 - 0.0157)
If incorrect, check the brake auto-adjusting system.

5. Turn the adjuster nut so that the parking brake lever travels
6 to 8 notches when pulled up with a force 30 kg (66 lbs.).
6. Make sure there is not brake dragging.

5C-44 BRAKES
REAR DRUM BRAKE ASSEMBLY
DISASSEMBLY

First, disassemble the brake drum. Then disassemble the rear brake assembly.
Refer to the “REAR AXLE ” section for the brake drum disassembly procedure.

RTW35CMF000201

MAJOR COMPONENTS
Disassembly Steps

1. Spring ; adjuster
2. Ring ; Adjuster lever
3. Lever ; adjuster

4. Spring ; Shoe hold
5. Pin ; Shoe hold

6. Spring ; Shoe to shoe, lower
7. Adjuster assembly
8. Spring ; shoe to shoe, upper
9. Shoe ; leading

10. Shoe ; trailing
11. Spring ; lever return
12. Retainer
13. Washer ; lever
14. Lever ; parking
15. Bolt ; wheel cylinder
16. Wheel cylinder assembly
17. Cover
18. Back plate

MINOR COMPONENTS
Disassembly Steps
Wheel Cylinder Assembly (14)

19. Piston
20. Cup
21. Boot ; piston

22. Return spring
23. Bleeder
24. Cap ; bleeder

BRAKES 5C-47
REASSEMBLY

RTW35CMF000301

MINOR COMPONENTS
Reassembly Steps
Wheel cylinder Assembly (7)

1. Piston assembly
2. Cup ; piston
3. Return spring



4. Boot ; piston

5. Bleeder
6. Cap ; bleeder

MAJOR COMPONENTS
Reassembly Steps

7. Back plate
8. Cover

9. Wheel cylinder assembly

10. Bolt ; wheel cylinder

11. Shoe ; leading

12. Lever ; parking

13. Washer ; lever

14. Retainer
15. Spring ; lever return



16. Shoe ; trailing

17. Spring ; shoe to shoe, upper

18. Adjust assembly
19. Spring ; shoe to shoe ; lower

20. Lever ; adjuster

21. Ring ; Adjuster lever
22. Spring ; shoe hold

23. Pin ; shoe hold

24. spring ; adjuster

BRAKES 5C-49
308R300008







11. Shoe ; leading

Be sure to use new spring; shoe hold.
12. Lever ; parking
13. Washer ; lever
14. Retainer
Install the lever, the washer and the retainer to the leading
brake shoe.



Apply grease to the sliding surfaces of the lever and
brake shoe.

Be sure to use new retainer and washer.
305R300009



















16. Shoe ; trailing


Be sure to use new spring; shoe hold.
17. Spring ; shoe to shoe, upper
18. Adjuster assembly
1. Apply grease to each of the parts shown in the
illustration before installing the brake shoe.

Lever; adjuster-shoe

Adjuster-shoe



2. Clean the adjuster bolt (5) and the adjuster rods (1) (4).
Apply grease to the threaded portion of the adjuster bolt.
3. Install the adjuster rod to the adjuster bolt.
4.
Apply grease to the adjuster asm ends (2) (3). Set the
spring ; upper to the adjuster asm, then install them to
the brake shoe.

305R300010











5. Before setting the brake shoes, apply grease to the back
plate portions (1) contacting the brake shoe edge as
shown in the illustration.
6.
Apply grease to the wheel cylinder parts contacting the
brake shoe (2).
7. Install the brake shoe.
Note :


Be careful not to damage the wheel cylinder dust cover.


Do not allow the wheel cylinder piston to fly free.

PARKING BRAKE SYSTEM 5D-1

SECTION 5D
BRAKES
PARKING BRAKE SYSTEM
CONTENTS

Service Precaution .......................................... 5D-1
Service Precaution ....................................... 5D-1
General Description ...................................... 5D-1
Parking Brake Lever ........................................ 5D-2
Parking Brake Lever Assembly and
Associated Parts (Bench Seat) .................. 5D-2
Removal ....................................................... 5D-3
Installation............................................................
5D-3
Front Parking Brake Cable....................................
5D-5
Front Parking Brake Cable and Associated
Parts (Bench Seat).........................................
5D-5
Removal...............................................................
5D-6
Installation............................................................
5D-6
Parking Brake Lever...............................................
5D-8
Parking Brake Lever Assembly and Associated
Parts (Buckle Seat)....................................... 5D-8
Removal ....................................................... 5D-8
Installation .................................................... 5D-8
Parking Brake Rear Cable ............................... 5D-9
Parking Brake Rear Cable and Associated
Parts ............................................................ 5D-9
Removal ....................................................... 5D-10
Installation .................................................... 5D-10
Inspection and Repair ................................... 5D-11
Parking Brake Adjustment ............................ 5D-11
Main Data and Specifications........................... 5D-12
Troubleshooting ............................................ 5D-13


Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE
SRS COMPONENTS OR THE SRS WIRING, REFE
R
TO THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN
POSSIBLE AIR BAG DEPLOYMENT, PERSONAL
INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM
REPAIRS.

CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, o
r
other corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener.
When you install fasteners, use the correct
tightening sequence and specifications. Following
these instructions can help you avoid damage to
parts and systems.

General Description
Pulling up the parking brake lever by hand will set the
parking brake. By means of a ratchet type lock, the
lever can be held in that position until it is released. The
position of the lever is transmitted through cable/leve
r
systems to the rear wheels. These parts are designed
to obtain sufficient braking force even when parking on
slopes. When the parking brake is set, or when the
ignition SW is in the "ON" position, the brake warning
light illuminates. The rear wheel parking brake is a
leading-trailing brake (mechanical inside expansion
type) built in the rear drum brake. Parking brake
adjustment is made through the adjusting hole (bored
through back plate). Parking brake lever stroke should
be adjusted to 8

14 notches with 30kg (bench seat) o
r
6

8 notches with 30kg (bucket seat). Refer to “Parking
Brake Adjustment" in this section.

5D-2 PARKING BRAKE SYSTEM

Parking Brake Lever
Parking Brake Lever Assembly and Associated Parts (Bench Seat)



This illustration is based on RHD model.
740R300010

Legend

(1)
Front Console Assembly

(2)
Glove Box

(3)
Instrument Panel Driver Lower Cover Assembly

(4)
Driver Knee Bolster Assembly

(5)
Driver Air Bag


(6)
Steering Wheel/Steering Cowl

(7)
Meter Cluster Assembly

(8)
Dash Side Trim Cover

(9)
Front Piller Trim Cover

(10)
Instrument Panel Assembly & Cross Beam

PARKING BRAKE SYSTEM 5D-3







This illustration shows RHD model
LHD model is opposite.
RTW35DLH000101

Legend

(1)
Nut

(2)
Bolt and Washer

(3)
Adjust Nut

(4)
Bolt


(5)
Front Parking Brake Cable

(6)
Clip

(7)
Switch

(8)
Bolt

(9)
Parking Lever Assembly


Removal
1. Remove instrument panel assembly & cross beam
in legend numbers order.

Refer to section 10.
2. Bolts (2)(8) are already removed in step 1.
3. Remove adjust nut (3).
4. Pull out clip (6) and take out front parking brake
cable (5) from parking lever assembly (9).
5. Remove bolts (4) and nut (1) and take out parking
lever assembly (9).
6. Remove switch (7).
Installation
1. Install switch (7).
Torque: 1.5 N




m (0.15 kg




m/13 lb in)
2. Set parking lever assembly (9).
3. Install bolts (4) and nut (1) and tighten them to the
specified torque.
Torque: 15 N





m (1.5 kg





m/11 lb ft)
4. Set front parking brake cable (5) in parking leve
r
assembly (9).
5. Drive clip (6) into the outer cable groove of front
parking brake cable (5) at the outside of parking
lever assembly (9).

5D-4 PARKING BRAKE SYSTEM

6. Drive adjust nut (3) on the front end of front
parking brake cable (5) so that front ends of rea
r
parking brake fit into the rear end (equalizer) of
front cable (5).
7. Install instrument panel assembly & cross beam.

Refer to section 10.
8. Install bolts (2) (8) and tighten them to the
specified torque.
Torque: 15 N




m (1.5 kg




m/11 lb ft)
9. Install all parts removed when removal steps.

Refer to section 10.
10. When a parking cable is replaced, pull parking
brake lever with a force equivalent to operating
force: 490N (50 kg/110 lb), 10 times fo
r
conditioning.
11. Adjust nut (3) so that lever (9) goes through 8

14
notches, when pulled with a operation force o
f
294N (30 kg/66 lb) and check brake for no drag.

PARKING BRAKE SYSTEM 5D-5

Front Parking Brake Cable
Front Parking Brake Cable and Associated Parts (Bench Seat)


750R300003

Legend

(1)
Shift Knob (manual transmission)

(2)
Front Floor Console

(3)
Rear Cover

(4)
Bolt


(5)
Seat Assembly

(6)
Buckle: side seat and Center Seat Belt

(7)
Seat Adjuster