torque ISUZU AXIOM 2002 Service Repair Manual

5C±29 POWER±ASSISTED BRAKE SYSTEM
Inspection and Repair
Visual Check
Make necessary parts replacement if cuts, nicks,
excessive wear, or other abnormal conditions are found
through inspection. Check the following parts:

Yoke clevis

Valve body guard

Silencer

Filter plate and seal assembly
Installation
1. Install plate and seal assembly.
2. Install retainer.3. Install 2 gaskets and spacer.
4. Install filter.
5. Install silencer.
6. Install valve body guard.
7. Install retainer.
8. Install lock nut and yoke clevis and tighten to the
specified torque.
Torque: 20 N´m (15 lb ft)
9. Install vacuum booster, refer to
Vacuum Booster in
this section.
10. Install master cylinder, refer to
Master Cylinder in this
section and after installation, perform brake pedal
check and adjustment. Refer to
Brake Pedal in this
section.
Vacuum Booster Overhaul
Vacuum Booster
The vacuum booster cannot be disassembled for repair.
Replace a defective vacuum booster with a new one.

5C±30
POWER±ASSISTED BRAKE SYSTEM
Main Data and Specifications
General Specifications
Vacuum booster diaphragm diameter (Front)205 mm (8.07 in)
Vacuum booster diaphragm diameter (Rear)230 mm (9.06 in)
Push rod strokeMore than 32.0 mm (1.26 in)
Plunger diameter10.25 mm (0.40 in)
Push rod diameter27.4 mm (1.08 in)
Torque Specifications
330R200001

5C±34
POWER±ASSISTED BRAKE SYSTEM
302RW006
3. Carefyully use adjustable pliers to bottom the piston
into the caliper bore. Do not pull or twist the flexible
hose or damage will occur.
Install caliper assembly.
Set caliper assembly in place.
302RS008
4. Install lock bolt (5) and tighten the bolt to the specified
torque.
Torque: 74 N´m (54 lb ft)
302RW018
5. Install wheel and tire assembly, refer to Wheels and
Tires System
in Section 3E.
6. Pump the brake pedal several times to make sure that
the pedal is firm. Check the brake fluid level in the
reservoir after pumping the brakes.

5C±38
POWER±ASSISTED BRAKE SYSTEM
3. Install support bracket and tighten the bolt (7) to the
specified torque.
Torque: 155 N´m (115 lb ft)
302RW012
4. Install caliper assembly.
5. Install lock bolt (9) and guide bolt (8) and tighten the
bolt to the specified torque.
Torque: 74 N´m (54 lb ft)
302RW013
6. Install brake flexible hose, always use new gaskets
and be sure to put the hooked edge of the flexible
hose end into the anti±rotation cavity then tighten the
I±bolt (10) to the specified torque.
Torque: 35 N´m (26 lb ft)
302RW014
7. Install wheel and tire assembly, refer to Wheels and
Tires System
in Section 3E.
8. Bleed brakes. Refer to
Hydraulic Brakes in this
section.

5C±40
POWER±ASSISTED BRAKE SYSTEM
5. Insert a block of wood into the caliper and force out
the piston by blowing compressed air into the caliper
at the flexible hose attachment. This procedure must
be done prior to removal of the dust boot.
Remove piston.
WARNING: D O N O T P L A C E Y O U R F I N G E R S I N
FRONT OF THE PISTON IN AN ATTEMPT TO CATCH
OR PROTECT IT WHEN APPLYING COMPRESSED
AIR. THIS COULD RESULT IN PERSONAL INJURY.
CAUTION: Use just enough air to ease the piston
out of the bore. If the piston is blown out, it may be
damaged.
302RS017
6. Remove dust boot: piston.
7. Remove piston seal.
8. Remove bleeder with cap.
9. Remove caliper body.
Inspection and Repair
Make necessary parts replacement, if wear, damage,
corrosion or any other abnormal conditions are found
through inspection.
Check the following parts:

Rotor

Cylinder body

Cylinder bore

Piston

Guide bolt, lock bolt

Support bracket
NOTE: The piston seal, boot ring and dust boot are to be
replaced each time the caliper is overhauled. Discard
these used rubber parts and replace them with new ones.
Reassembly
1. Install caliper body.
2. Install bleeder with cap and tighten the cap to the
specified torque.
Torque: 8 N´m (69 lb in)
3. Apply special rubber grease to the piston seal and
cylinder wall, then insert the piston seal into the
cylinder. The special rubber grease is included in the
repair kit.
302RS018
4. When inserting the piston into the cylinder, use finger
pressure only and do not use a mallet or other impact
tool, since damage to the cylinder wall or piston seal
can result.
Install piston.
302RS019

5C±41 POWER±ASSISTED BRAKE SYSTEM
5. Apply special grease (approximately 1 g) to the piston
and attach the dust boot to the piston and caliper.
Insert the dust boot ring into the dust boot.
302RS020
6. Install guide bolt and lock bolt dust boot.
7. Install the dust boot on the support bracket after
applying special grease (approximately 1 g) onto the
dust boot inner surface. Apply special grease onto the
lock bolt and guide bolt setting hole of the support
bracket.
302RS021
8. Install lock bolt and guide bolt and tighten the bolt to
the specified torque.
Torque: 74 N´m (54 lb ft)

5C±42
POWER±ASSISTED BRAKE SYSTEM
Main Data and Specifications
General Specifications
TypeFloating, pin slide
Pad dimension55 cm
(8.52 in
)
Adjusting methodSelf±adjusting
Piston diameter60.33 mm (2.38 in)
Disc typeVentilated
Disc thickness26 mm (1.02 in)
Disc effective diameter222 mm (8.74 in)
Torque Specifications
E05RW004

5C±45 POWER±ASSISTED BRAKE SYSTEM
306RW005
3. Carefyully use adjustable pliers to bottom the piston
into the caliper bore. Do not pull or twist the flex hose
or damage will occur.
302RS008
4. Install lock bolt (5) and tighten the bolt to the specified
torque.
Torque: 44 N´m (32 lb ft)
5. Install wheel and tire assembly, refer to
Wheels and
Tires System
in Section 3E.
6. Pump the brake pedal several times to make sure that
the pedal is firm. Check the brake fluid level in the
reservoir after pumping the brakes.
306RW006

5C±49 POWER±ASSISTED BRAKE SYSTEM
Installation
1. Install clip (4).
306RW010
2. Apply special grease (approximately 0.2 g) to both
contacting surfaces of the inner shims (5). Wipe off
extruded grease after installing. Install pad assembly
with shim.
306RW011
Legend
(5) Inner Shim
(6) Wear indicator
3. Install support bracket and tighten the bolt (7) to the
specified torque.
Torque: 103 N´m (76 lb ft)
306RW012
4. Install caliper assembly.
5. Install lock bolt and guide bolt (8) and tighten the bolt
to the specified torque.
Torque: 44 N´m (32 lb ft)
306RW013
6. Install brake flexible hose, always use new gaskets
and be sure to put the hooked edge of the flexible
hose end into the anti±rotation cavity then tighten the
eye±bolt (9) to the specified torque.
Torque: 35 N´m (26 lb ft)

5C±51 POWER±ASSISTED BRAKE SYSTEM
Disassembly
1. Remove guide bolt.
2. Remove lock bolt.
3. Remove dust boot; guide bolt and lock bolt.
4. Remove dust boot ring, using a small screwdriver.
302RS016
5. Insert a block of wood into the caliper and force out
the piston by blowing compressed air into the caliper
at the flexible hose attachment. This procedure must
be done prior to removal of the dust boot.
Remove piston.
WARNING: D O N O T P L A C E Y O U R F I N G E R S I N
FRONT OF THE PISTON IN AN ATTEMPT TO CATCH
OR PROTECT IT WHEN APPLYING COMPRESSED
AIR. THIS COULD RESULT IN PERSONAL INJURY.
CAUTION: Use just enough air to ease the piston
out of the bore. If the piston is blown out, it may be
damaged.
302RS017
6. Remove dust boot: piston.
7. Remove piston seal.
8. Remove bleeder with cap.
9. Remove caliper body.
Inspection and Repair
Make necessary parts replacement, if wear, damage,
corrosion or any other abnormal conditions are found
through inspection.
Check the following parts:

Rotor

Cylinder body

Cylinder bore

Piston

Guide bolt, lock bolt

Support bracket
NOTE: The piston dust seal and dust boot are to be
replaced each time the caliper is overhauled. Discard
these used rubber parts and replace with new ones.
Reassembly
1. Install caliper body.
2. Install bleeder with cap and tighten the cap to the
specified torque.
Torque: 8 N´m (69 lb ft)
3. Install piston seal and apply special rubber grease to
the piston seal and cylinder wall, then insert the piston
seal into the cylinder. The special rubber grease is
included in the repair kit.
302RS018
4. When inserting the piston into the cylinder, use finger
pressure only and do not use a mallet or other impact
tool, since damage to the cylinder wall or piston seal
can result.
Install piston.