torque ISUZU AXIOM 2002 Service Repair Manual

5C±115 POWER±ASSISTED BRAKE SYSTEM
Machining The Drum
If a drum is to be machined, only enough metal should be
removed to obtain a true, smooth braking surface. If a
drum does not clean-up when machined to a maximum
diameter, it must be replaced. Removal of more metal willaffect dissipation of heat and may cause distortion of the
drum.
After refinishing, replace any drum that exceeds a
maximum inside diameter of 296.5 mm (11.673 in). Do
not use a brake drum that is not within the specification.
Maximum inside diameter: 296.5 mm (11.673 in)
Wheel Cylinder Assembly (4y2 Model)
Wheel Cylinder Assembly and Associated Parts
305RW003
Legend
(1) Brake Linings
(2) Wheel Cylinder(3) Bolts
(4) Brake Pipe
Removal
1. Remove brake linings (1).

Refer to
Brake Lining and Associated Parts in this
section.
2. Remove brake pipe (4).

Plug the opening in the line to prevent fluid loss and
contamination.
3. Remove bolts (3) and wheel cylinder (2).
Installation
1. Install wheel cylinder (2) and tighten bolts (3) to the
specified torque.
Torque: 10 N´m (8 lb ft)
2. Install brake pipe (4) and tighten the nut to the
specified torque.
Torque: 16 N´m (12 lb ft)
3. Install brake linings (1).

Refer to
Brake Lining Replacement in this section.

Bleed brake system. Refer to
Hydraulic Brake in
this section.

5C±116
POWER±ASSISTED BRAKE SYSTEM
Disassembled View
305RS006
Legend
(1) Boot
(2) Piston Assembly
(3) Piston Cup
(4) Return Spring
(5) Bleeder
(6) Wheel Cylinder
Disassembly
1. Remove boot (1) and piston assembly (2).
2. Remove piston cup (3) from piston assembly (2).
3. Remove return spring (4) and bleeder (5) from wheel
cylinder (6).
Inspection and Repair
1. Make necessary parts replacement if wear, damage,
corrosion or any other abnormal condition are found
through inspection.
Check the following parts;

Wheel cylinder body

Cylinder bore

Piston

Return spring

Bleeder
NOTE: Replace the piston cups and boots each time the
wheel cylinder is overhauled. Discard these used rubber
parts and replace with new ones.
Reassembly
1. Lubricate the cylinder bore with clean rubber grease.
305RS007
2. Install bleeder (5) to wheel cylinder (6).
Torque: 10 N´m (8 lb ft)
305RS008

5C±118
POWER±ASSISTED BRAKE SYSTEM
Main Data and Specifications
General Specifications
Rear drum brake
TypeLeading-trailing, non-servo
Drum inside diameter295 mm (11.6 in)
Wheel cylinder diameter22.22 mm (7/8 in)
Torque Specifications
E05RW010

5D1±1
PARKING BRAKE SYSTEM (4x4 Model)
AXIOM
BRAKES
PARKING BRAKE SYSTEM (4y4 Model)
CONTENTS
Service Precaution 5D1±1. . . . . . . . . . . . . . . . . . . . . .
General Description 5D1±1. . . . . . . . . . . . . . . . . . . . .
Operation 5D1±2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parking Brake Lever and Front Cable 5D1±3. . . . . .
Parking Brake Lever Assembly and
Associated Parts 5D1±3. . . . . . . . . . . . . . . . . . . . . .
Removal 5D1±3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5D1±3. . . . . . . . . . . . . . . . . . . . . . . . . . . . Parking Brake Rear Cable 5D1±4. . . . . . . . . . . . . . . .
Parking Brake Rear Cable and Associated
Parts 5D1±4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 5D1±5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5D1±5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 5D1±6. . . . . . . . . . . . . . . . . .
Parking Brake Adjustment 5D1±6. . . . . . . . . . . . . . . .
Main Data and Specifications 5D1±7. . . . . . . . . . . . .
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, REFER 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, or other
corrosion inhibitors) on threaded fasteners or
fasteners joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fasteners.
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/lever 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 theªONº position, the brake warning light illuminates.
The rear wheel parking brake is a duo±servo brake
(mechanical inside expansion type) built in the rear disc
brake. Parking brake adjustment is made through the
adjusting hole (bored through back plate). Parking brake
lever stroke should be adjusted to 6±8 notches. Refer to
Parking Brake Adjustment in this section.

5D1±3
PARKING BRAKE SYSTEM (4x4 Model)
Parking Brake Lever and Front Cable
Parking Brake Lever Assembly and Associated Parts
311R200001
Legend
(1) Rear Console
(2) Switch Connector
(3) Bolt
(4) Adjust Nut and Lock Nut(5) Trunnion Pin
(6) Equalizer
(7) Parking Brake Rear Cable
(8) Parking Brake Lever
Removal
1. Remove rear console (1).

Refer to
Body and Accessories section in this
manual.
2. Disconnect switch connector (2).
3. Remove bolt (3).
4. Remove adjust nut and lock nut (4).
5. Pull out equalizer (6) from trunnion pin (5).
6. Disconnect trunnion pin (5) from Parking brake lever
(8).
7. Disconnect parking brake rear cable (7).
Installation
1. Apply grease (BESCO L±2 or equivalent) to the
connecting portion of the rear cable (7) and equalizer
(6).
2. Connect parking brake rear cable (7) to equalizer
3. Install trunnion pin (5) to parking brake lever (8).
4. Insert equalizer (6) into trunnion pin (5) and tighten
adjust nut and lock nut (4).

To adjust the parking brake lever, see ªParking
Brake Adjustmentº in this section.
Lock Nut Torque: 13 N´m (113 lb in)
5. Tighten the parking brake lever fixing bolt (3) to the
specified torque.
Torque: 15 N´m (11 lb ft)
6. Connect switch connector (2).
7. Install rear console (1).

Refer to
Body and Accessories section in this
manual.

5D1±5
PARKING BRAKE SYSTEM (4x4 Model)
Removal
1. Remove rear wheels (1).
2. Remove 2 bolts to remove the caliper assembly (2)
from the support bracket. Refer to
ªRear Disc Brakesº
in Power Assisted Brake System
section. Temporarily
hang the caliper with wire etc.
3. Remove rotor (drum) (3).
4. Remove holding spring (4), upper return spring (5)
and lower return spring (6).
5. Previously remove the rear cable from the parking
brake lever, then remove the brake shoe assembly
(7).
308RW004
Legend
(1) Parking Brake Lever
6. Remove cable fixing bolt (8) and bolt (9) (10) (11).
7. Remove nut (12).
8. Remove nut (13) and retainer (14).
9. Remove rear cable (15).
Installation
1. Apply grease (BESCO L±2 or equivalent) to the
connecting portion of the rear cable and equalizer.
Install rear cable (15).
2. Install retainer (14).

Tighten nut (13) to the specified torque.
Torque: 41N´m (30lb ft)
3. Tighten nut (12) to the specified torque.
Torque: 15N´m (11lb ft)
4. Tighten bolt (11) (10) (9) to the specified torque.
Torque: 6.5N´m (57lb in)

To adjust the parking brake, refer to
Parking Brake
Adjustment
in this section.
5. Tighten the cable fixing bolt (8) to the specified
Torque: 6.5N´m (57lb in)6. Install shoe assembly (7).
After installation of the shoe and cable assembly,
apply special grease (included in the repair kit) to the
following portions indicated in the figure.
308RS005
7. Install lower return spring (6) and upper return spring
(5).
The parking brake lever side (secondary side) return
spring must be installed on the outer side of the
primary side return spring.
308RS003
Legend
(1) Outer Side
(2) Parking Lever
8. Install holding spring (4).
9. Install rotor (drum) (3).
10. Install caliper assembly (2).
11. Install rear wheels (1).

5D1±6
PARKING BRAKE SYSTEM (4x4 Model)
Inspection and Repair
Parking Brake Lining Inspection
Check the shoe assemblies for wear by removing the
brake drum.
Replace the shoe assemblies if the lining thickness is less
than 1.0 mm (0.039 in).
Minimum limit: 1.0 m (0.039 in)
308RS004
Parking Brake Rotor (Drum) Inspection
Refer to ªRear Disc Brakesº in Power-Assisted Brake
System
section for inspection procedure of the rotor
(drum).
Parking Brake Adjustment
1. Prior to lever stroke adjustment, adjust rear brake
shoe/rotor (drum) gap. Perform this procedure with
loosening the adjust nut of the hand brake lever.
2. Remove the adjusting hole plug (rubber) and turn the
shoe adjusting screw downward with a small
screwdriver so that shoes will expand until they get
into close touch with the rotor. (Turn down the
adjusting screw notch by notch until the rotor does not
turn.)
3. Turn the adjusting screw in the opposite direction
(upward) until the rotor can be turned lightly. Standard
number of notches to turn upward: 7 or 8 notches
Turn the rotor and make sure that there is no brake
dragging.
4. After the rear brake shoe/rotor (drum) gap has been
adjusted, perform parking brake cable adjustment.
5. Turn the adjusting nut so that the parking brake lever
travels 6±8 notches when pulled up with a force of 30
kg (66 lb).
6. Make sure there is no brake dragging. Then tighten
the cable lock nut
Torque : 13 N´m (113 lb in)7. When poor braking effect possibly resulting from
insufficient break±in is felt, or just after replacement
of parking brake shoe, be sure to conduct break±in as
follows:
8. Forward 50 km/h (30 mph) y 400 m (About 30
seconds) with a lever pull force of 15 kg (33 lb).
9. Backward 10 km/h (6 mph) y 50 m (About 18
seconds) with a lever pull force of 15 kg (33 lb).
NOTE: Break±in procedures must be performed under
safe conditions and traffic rules.

If braking effect still remains poor after the above
break±in, wait for some time until parking brake shoe
cools down and repeat the procedures 8. and 9. noted
above.

On completion of break±in, inspect parking brake
lever stroke, and if the lever does not come within the
specified number of notches when pulled up,
readjust.

Excessive break±in may cause premature wear of
the parking brake lining.

5D1±7
PARKING BRAKE SYSTEM (4x4 Model)
Main Data and Specifications
General Specifications
Model
TypeDuo±servo
Drum inside diameter210 mm(8.27 in)
Parking brake lever stroke6±8 notches
When pulled with a force of 30 kg (66 lb)
Torque Specifications
311R200002

PARKING BRAKE SYSTEM (4X2 Model)
5D2±1
AXIOM
BRAKES
PARKING BRAKE SYSTEM (4y2 Model)
CONTENTS
Service Precaution 5D2±1. . . . . . . . . . . . . . . . . . . . . .
General Description 5D2±1. . . . . . . . . . . . . . . . . . . . .
Parking Brake Lever 5D2±2. . . . . . . . . . . . . . . . . . . . .
Parking Brake Lever Assembly and
Associated Parts 5D2±2. . . . . . . . . . . . . . . . . . . . . .
Removal 5D2±2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5D2±2. . . . . . . . . . . . . . . . . . . . . . . . . . . . Parking Brake Rear Cable 5D2±3. . . . . . . . . . . . . . . .
Parking Brake Rear Cable and Associated
Parts 5D2±3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 5D2±4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5D2±4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parking Brake Adjustment 5D2±4. . . . . . . . . . . . . . . .
Main Data and Specifications 5D2±5. . . . . . . . . . . . .
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, REFER 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, or 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/lever 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 theªONº position, the brake warning light illuminates.
The rear wheel parking brake is a leading/trailing brake
(mechanical inside expansion type). Parking brake
adjustment is made through the adjusting hole (bored
through back plate). Parking brake lever stroke should be
adjusted to 6 notches. Refer to
Parking Brake Adjustment
in this section.

5D2±2
PARKING BRAKE SYSTEM (4X2 Model)
Parking Brake Lever
Parking Brake Lever Assembly and Associated Parts
311R200001
Legend
(1) Rear Console
(2) Switch Connector
(3) Bolt
(4) Adjust Nut and Lock Nut(5) Trunnion Pin
(6) Equalizer
(7) Parking Brake Rear Cable
(8) Parking Brake Lever
Removal
1. Remove rear console (1).

Refer to
Body and Accessories section in this
manual.
2. Disconnect switch connector (2).
3. Remove bolt (3).
4. Remove adjust nut and lock nut (4).
5. Pull out equalizer (6) from trunnion pin (5).
6. Disconnect trunnion pin (5) from parking brake lever
(8).
7. Disconnect parking brake rear cable (7).
Installation
1. Apply grease (BESCO L±2 or equivalent) to the
connecting portion of the rear cable (7) and equalizer
(8).
2. Connect parking brake rear cable (7) to equalizer (6).
3. Install trunnion pin (5) to parking brake lever (8).
4. Insert equalizer (6) into trunnion pin (5) and tighten
adjust nut and lock nut (4).

To adjust the parking brake lever, see ªParking
Brake Adjustmentº in this section.
Lock Nut Torque: 13 N´m (113 lb in)
5. Tighten parking lever fixing bolt (3) to the specified
torque.
Torque: 15 N´m (11 lb ft)
6. Connect switch connector (2).
7. Install rear console (1).

Refer to
Body and Accessories section in this
manual.