brake fluid ISUZU TF SERIES 2004 Owner's Manual

5C-52 BRAKES
MASTER CYLINDER
REMOVAL AND INSTALLATION

MASTER CYLINDER ASSEMBLY



This illustration is based on RHD model.
330R300008

Removal Steps

1. Brake line
2. Nut ; master cylinder to vacuum booster
3. Master cylinder assembly

Installation Steps
3. Master cylinder assembly

2. Nut ; master cylinder to vacuum booster

1. Brake line




Important Operation - Removal
1. Brake Line
Be very careful not to spill brake fluid on the painted surface.
Damage to the painted surface will result.








Important Operation - Installation
2. Nut ; Master Cylinder to Vacuum Booster
Torque N
m (kgf
m/lb
ft)
12 – 18 (1.2 – 1.8 / 9 – 13)

1. Brake Line
Torque N

m (kgf

m/lb

ft)
13 – 19 (1.3 – 1.9 / 9 – 14)

BRAKES 5C-53
DISASSEMBLY

RTW35CMF000401

Disassembly Steps
1. Cap
2. Diaphragm
3. Bolt
4. Resever tank
5. Grommet




6. Snap ring

7. Stop pin

8. Primary piston

9. Secondary piston
10. Cylinder body


Note :
 Be sure to replace the designated with new ones.
 Wash the disassembled parts in clean brake fluid.
 Use compressed air to clean the ports.
 Do not allow dirt and dust to contaminate the disassembled
parts.

5C-54 BRAKES
Important Operations
When disassembling, inspecting or reassembling the master
cylinder assembly, take care not to bring the parts into contact
with mineral oil or dust. Wash the piston cups only with brake
fluid. Do not use gasoline or other mineral-base cleaning
solvents.



6. Ring ; Snap
Remove the snap ring from the cylinder body with pushing in
the primary and secondary pistons.
7. Stop Pin
Remove the stop pin from the cylinder body with pushing in the
primary and secondary pistons.


8. Piston Assembly ; Primary and Spring
9. Piston Assembly ; Secondary and Spring
Don’t remove the spring from the piston.

BRAKES 5C-55
INSPECTION AND REPAIR

Make necessary correction or parts replacement if wear damage or any other abnormal conditions are found
through inspection.




Cylinder inside face


Piston


Piston cap


Piston cap spacer


Return port

Return spring


Visual Check
Inspect the following parts for wear, distortion, cuts, nicks,
corrosion, or other abnormal conditions.



Return Port
Check the return port for obstructions and if necessary, clean
with a tag wire.
Blow away foreign matter with compressed air.



Primary Piston
After reassembly, push in the primary piston to see that returns
smoothly.
Repeat the test two or three times to see that brake fluid is
forced out from the front and rear outlets.

5C-56 BRAKES
REASSEMBLY



Reassembly Steps
1. Secondary piston
2. Primary piston
3. Cylinder body
4. Grommet
5. Reservoir tank


6. Stop pin
7. Bolt
8. Snap ring
9. Diaphragm
10. Cap




1. Secondary piston
Lubricate the piston cups on the secondary piston assemblies
with brake fluid.
Note :
Be sure to use a new piston.









2. Primary piston
Lubricate the piston cups on the primary piston assemblies
with brake fluid (1) and the rubber grease (2).
Note :
Be sure to use a new piston.

BRAKES 5C-59
330R300002
Important Operation-Removal
1. Brake pipe
When hurdling, be careful not to spill brake fluid over the
painted surfaces, as damage to the paint finish will result.
2. Master Cylinder Fixing Nut
3. Bracket (only RHD model)
4. Master Cylinder Assembly
NOTE:
When removing the master cylinder from the vacuum booster,
be sure to get rid of the internal negative pressure of the
vacuum booster (by, for instance, disconnecting the vacuum
hose) in advance.
If any negative pressure remains in the vacuum booster, the
piston may possibly come out when the master cylinder is
being removed, letting the brake fluid run out.
While removing the master cylinder, further, do not hold the
piston as it can be easily pulled out.

7C-20 CLUTCH

AIR BLEEDING
Bleed air from clutch operating cylinder according to the
following procedure.
Carefully monitor fluid level at master cylinder during bleeding
operation.



1. Set the paking brake.



2. Top up reservoir with recommended brake fluid.
3. Connect a transparent vinyl tube to air bleeder valve.



4. Fully depress clutch pedal several times.



5. With clutch pedal depressed, open bleeder valve to release
air.
6. Close bleeder valve.
7. Repeat steps 5 through 6 above until brake fluid flows from
air bleeder valve without air bubbles.
8. Bleed air from clutch damper according to the above
procedure.
9. Repeat the above bleeding procedure until the air
completely removed.

CLUTCH 7C-35
SLAVE CYLINDER (4J, C24SE)
DISASSEMBLY



Disassembly Steps


1. Boot
2. Push rod
3. Piston and piston cup


4. Spring
5. Cylinder body




Important Operations
1. Boot
Brake fluid spilled on painted or plastic surfaces will cause
serious damage.
Take care not to spill brake fluid.

CLUTCH 7C-37
REASSEMBLY



Reassembly Steps


1. Cylinder body
2. Spring


3. Piston and piston cup


4. Push rod
5. Boot







Important Operations
1. Cylinder Body
1) Clean the cylinder body.
2) Apply brake fluid to the cylinder bore.


3. Piston and piston Cup
1) Apply brake fluid to the piston and piston cup.
2) Install the cups to the piston.
Note the installation direction of the piston cups in the
illustration.
3) Install the piston and piston cup to the cylinder body.

ELECTRICAL-BODY AND CHASSIS 8A-261
2. Even when the parking brake lever is pulled, the indicator light does not go off

Checkpoint Trouble Cause Countermeasure

Adjust the SW. installation
position or replace the parking
brake SW. Incorrect the parking brake
SW. adjustment or brake SW.
faulty
NG Thermo unit malfunction
Replace the brake fluid level
SW., or vacuum SW., or
repair a short circuit between
the parking brake SW.
connector 1
C-39
(Lever: 1
R-4) and 9 B-23
or the brake fluid level SW.
connector 2
C-37 and 9
B-23, (or the vacuum SW.
connector 1
C-38 and 9
B-23 : 4JH1-TC ONLY)
Check to see if the indicator
light goes off when the parking
brake SW. connector 1
C-39
(Lever: 1
R-4) is
di t d
Brake fluid level SW. or
vacuum SW. faulty or short
circuit
NG OK

Parking brake SW. installation
position and function




3. Oil pressure warning light does not go off while engine is running


Refer to ENGINE Section

Refer to ENGINE Section
NG Thermo unit malfunction

Repair a short circuit between
1
E-1 and 3 B-24

Check to see the warning light
goes off when the oil pressure
SW. connector
1
E-1 is disconnected


Short circuit


Replace the oil pressure unit
(or the oil pressure SW.)
Continuity between the oil
pressure SW. connector
1
E-1 and the body ground
when the engine is operating


Oil pressure unit (or oil
pressure SW) faulty
NG NG OK
OK

Engine oil pressure