ISUZU AXIOM 2002 Service Repair Manual

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±43 POWER±ASSISTED BRAKE SYSTEM
Rear Disc Brake Pads (4y4 Model)
Brake Pads Inspection
Check the outer pads by looking at each caliper from
above. Check the thickness on the inner pad by looking
down through the inspection hole in the top of the caliper.
Whenever the pad is worn to about the thickness of the
pad base, the pad should be removed for further
measurements. The pad should be replaced anytime the
pad thickness (1) is worn to within 1.0 mm (0.039 in) of the
pad itself.
Wear indicators are installed on disc brake pads, disc
brake pads need replacement when the wear indicator is
heard.
Minimum limit (1): 1.0 mm (0.039 in)
302RW016
Brake Pads and Associated Parts
306RW001
Legend
(1) Caliper Assembly
(2) Clip(3) Lock Bolt
(4) Pad Assembly

5C±44
POWER±ASSISTED BRAKE SYSTEM
Removal
NOTE: If a squealing noise occurs from the rear brake
while driving, check the pad wear indicator plate. If the
indicator plate contacts the rotor, the disc pad assembly
should be replaced.

Draw out two±thirds of the brake fluid from the
reservoir.

Raise the vehicle and support it with suitable safety
stands.
1. Remove wheel and tire assembly, refer to
Wheels
and Tires System
in Section 3E.
2. Remove lock bolt (1)
306RW002
3. Rotate caliper assembly and support the caliper
assembly so that the brake hose is not stretched or
damaged.
4. Remove pad assembly with shim.
5. Remove clip.
Installation
1. Install clip (2).
306RW003
2. Apply special grease (approximately 0.2 g) to both
contacting surfaces of the inner shims. Wipe off
extruded grease after installing. Install pad assembly
with shim.
306RW004
Legend
(3) Inner Shim
(4) Wear Indicator

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±46
POWER±ASSISTED BRAKE SYSTEM
Rear Disc Brake Rotor (4y4 Model)
Inspection
In the manufacturing of the brake rotor, all the tolerances
regarding surface finish, parallelism and lateral runout are
held very closely. Maintaining these tolerances provides
the surface necessary to assure smooth brake operation.
Lateral Runout
Lateral runout is the movement of the rotor from side to
side as it rotates on the spindle. This could also be
referred to as ªrotor wobbleº.
This movement causes the piston to be knocked back into
its bore. This results in additional pedal travel and a
vibration during braking.
Checking Lateral Runout
1. Adjust the wheel bearing correctly, refer to Differential
in Section 4A1.
2. Attach the dial indicator accordingly so that the stem
contacts the rotor surface to approximately 29mm
(1.14 in) from the rotor edge.
3. Rotate the rotor one complete turn and inspect for
signs of lateral runout. Lateral runout should not
exceed 0.13 mm (0.005 in).
1. The lateral runout should not exceed 0.13 mm
(0.005 in)
Maximum runout: 0.13 mm (0.005 in)
306RY00013
Parallelism
Parallelism is the measurement of thickness of the rotor
at four or more points around the circumference of the
rotor. All measurement must be made at 22 mm (0.87 in)
from the edge of the rotor.
The rotor thickness must not vary more than 0.010 mm
(0.0004 in) from point to point.
Maximum parallelism: 0.010 mm (0.0004 in)
420RS013
Replacing Brake Rotors
When installing new brake rotors, do not refinish the
surfaces. These parts are at the correct level of surface
finish.
Refinishing Brake Rotors
Accurate control of the rotor tolerances is necessary for
proper performance of the disc brakes. Machining of the
rotor should be done only with precision equipment. All
brake rotors have a minimum thickness dimension cast
into them. This dimension is the minimum wear
dimension and not a refinish dimension. The minimum
wear dimension is 16.6 mm (0.654 in). The minimum
refinish dimension is 16.97 mm (0.668 in).
When refinishing rotors, always use sharp cutting tools or
bits. Dull or worn tools leave a poor surface finish which
will affect initial braking performance. Vibration
dampening attachments should always be used when
refinishing braking surfaces. These attachments
eliminate tool chatter and will result in better surface
finish.

5C±47 POWER±ASSISTED BRAKE SYSTEM
After refinishing, replace any rotor that does not meet the
minimum thickness of 16.97 mm (0.668 in). Do not use a
brake rotor that exceeds the manufacturers
specifications.
Minimum wear dimension: 16.6 mm (0.654 in)
Refinish dimension: 16.97 mm (0.668 in)
420RW002
Rear Drum (In Disc) Inside Diameter
Check
Check the rear drum inside diameter by measuring at
more than two portions as shown in the illustration.
If the inside diameter is greater than the limit, replace the
rear rotor.
Standard: 210.0 mm (8.27 in)
Limit: 211.4 mm (8.32 in)
420RS035

5C±48
POWER±ASSISTED BRAKE SYSTEM
Rear Disc Brake Caliper Assembly (4y4 Model)
Rear Disc Brake Caliper Assembly and Associated Parts
306RW007
Legend
(1) Brake Flexible Hose
(2) Clip
(3) Lock Bolt(4) Support Bracket
(5) Guide Bolt
(6) Pad Assembly with Shim
(7) Caliper Assembly
Removal
1. Raise the vehicle and support with suitable safety
stands.
2. Remove wheel and tire assembly, refer to
Wheels
and Tires System
in Section 3E.
3. Remove the bolt and gaskets, then disconnect the
flexible hose from the caliper and after disconnecting
the flexible hose (1), cap or tape the openings to
prevent entry of foreign material.
306RW008
4. Since the brake fluid flows out from the connecting
coupler, place a drain pan under the vehicle.5. Remove lock bolt (3).
6. Remove guide bolt (2).
306RW009
7. Remove caliper assembly.
8. Remove support bracket with pad assembly and take
care not to damage the flexible brake hose when
removing the support bracket.
9. Remove pad assembly with shim and mark the lining
locations if they are to be reinstalled.
10. Remove clip.

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±50
POWER±ASSISTED BRAKE SYSTEM
302RW017
7. Install the wheel and tire assembly, refer to Wheels
and Tires System
in Section 3E.
8. Bleed brakes. Refer to
Hydraulic Brakes in this
section.
Rear Disc Brake Caliper (4y4 Model)
Rear Disc Brake Caliper Disassembled View
306RW014
Legend
(1) Guide Bolt
(2) Lock Bolt
(3) Bleeder with Cap
(4) Caliper Body(5) Piston Seal
(6) Piston
(7) Dust Boot: Piston
(8) Dust Boot Ring
(9) Dust Boot: Guide Bolt and Lock Bolt