brake ISUZU TF SERIES 2004 Workshop Manual

5C-34 BRAKES



Important Operations - Removal
1. Brake Flexible hose
Remove the bolt and gasket and disconnect the brake flexible
hose from the caliper.
After disconnecting the flexible hose, cap or tape the openings
to prevent entry of foreign material.



2. Lock Bolt
Remove the lock bolt from the caliper.



3. Pad Assembly with Shim
Rotate the caliper upward.



Mark the lining locations if they are to be reinstalled.

BRAKES 5C-35



6. Support Bracket
Take care not to damage the flexible brake hose when
removing the support bracket.



7. Front Hub and Disc Assembly
For the removal procedure, refer to Section 4C "FRONT
WHEEL DRIVE".



Important Operations - Installation
7. Front Hub and Disc Assembly
For the installation procedure, refer to the front hub and disc
reassembly procedure in Section 4C "FRONT WHEEL
DRIVE".

5C-36 BRAKES


6. Support Bracket
Torque N
m(kgf
m/lb
ft)
196 - 235 (20.0 – 24.0 / 145 - 174)
Set up the clip and pad before installation of the support
racket.
4. Clip ; Pad
Install new parts if necessary.


2. Lock Bolt
Torque N

m(kgf

m/lb

ft)
32 - 40 (3.3 – 4.1 / 24 - 30)






1. Brake Flexible Hose
Attach the bolt and new gasket
Torque N
m(kgf
m/lb
ft)
29 -39 (3.0 - 4.0 / 22 - 29)

After installation, bleeding and replenishing procedure must be
performed.
Wipe the circumference of the hose clean.
Note:






Always use new gaskets.

Be sure to put the hooked edge of the flexible hose end into
the anti-rotation cavity.

BRAKES 5C-37

REMOVAL AND INSTALLATION OF DISC PAD




Removal Steps
1. Lock Bolt
Remove the lock bolt from the caliper.
Note:
Don't remove the brake hose from caliper when replacing
pads.



2. Rotate the Caliper Upward
Remove the caliper from the support bracket and the caliper to
the upper link or the frame.
Note:
While caliper is removed from support bracket, never step
on the brake pedal or the piston will protrude rapidly.




3. Pad Assembly with Shim
Remove the pad assembly with the shim.
Mark the pad locations if they are to be reinstalled.



4. Clip ; Pad
Discard the used clip and install a new one.



Installation Steps
1. Clip ; Pad
2. Pad Assembly with Shim
After attaching the pad assembly with the shim to the support
bracket, position the wear indicator to the lower side of the
inner pad and position the wear indicator to the upper side of
the outer pad.

5C-38 BRAKES





3. Caliper Assembly
Lower the caliper into its original position.
Do not damage the flexible hose by twisting or pulling it.


4. Lock Bolt
Attach the lock bolt to the caliper.
Torque N
m(kgf
m/lb
ft)
32 - 40 (3.3 – 4.1 / 24 - 30)

BRAKES 5C-39
DISASSEMBLY

CALIPER ASSEMBLY


Disassembly Steps
1. Bleeder with cap

2. Piston
3. Dust seal; piston
4. Ring seal
5. Body; caliper








Important Operations


2. Piston (with Ring Seal)
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 dust seal.

CAUTION:
Do not place your fingers in front of the piston in an
attempt to catch or protect it when applying compressed
air.

5C-40 BRAKES
INSPECTION AND REPAIR

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





Rotor


Caliper body

Cylinder bore


Piston


Support bracket


Lock bolt


Guide pin



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




Rotor

Thickness (t) mm(in)

Standard Replacement
thickness (Discard)
4

2 26.0 (1.024) 24.6 (0.969)
4

2 HIGH RIDE
4
4 27.0 (1.063) 25.6 (1.008)



Run out
Limit mm(in)
0.075 (0.0029)

Before inspection, adjust the wheel bearing correctly.
Using a dial gauge, measure the run out at the 10mm inside
position from rotor out side edge of disc pad contact surface.




Parallelism (Total circumferential thickness variation)
Limit mm(in)
0.023 (0.0009)

Contact surface must be within 0.023mm at the 10mm inside
position from rotor out side edge.
(Measurement; shall be measure more than 8 position at
circumferential direction.)

BRAKES 5C-41











Thickness of Disc Pad
Thickness (t) mm(in)

Standard Limit
10.0 (0.394) 1.8 (0.071)

Replace the front disc pad whenever the pad wear indicator
makes a squeaking noise or when the pad is worn to within 1.8
mm of the shoe table.

All four brake pads should be replaced together.

302R300019


Seal and Boot
The dust seal, dust boot and ring seal are to be replaced each
time the caliper is overhauled.
Discard thee used rubber parts.

5C-42 BRAKES
REASSEMBLY
CALIPER ASSEMBLY


Disassembly Steps
1. Body ; caliper
2. Ring seal
3. Dust seal ; piston
4. Piston
5. Bleeder
6. Cap





Important Operations
1. Body ; Caliper
2. Ring Seal
Apply clean brake fluid to the ring seal and cylinder wall, then
insert the ring seal into the cylinder.
Ensure that the piston ring seal are not twisted in the caliper
bore grooves.

BRAKES 5C-43

3. Dust seal ; Piston
Install the dust seal on the pistons.
4. Piston
Apply clean brake fluid to the piston, the dust seal is certainly
put into the slot on the piston and attach the caliper.
When inserting the piston into the cylinder, use finger pressure
only. Do not use a mallet or other impact tools, since damage
to the cylinder wall or ring seal can result.
The movement of a caliper piston into a caliper bore should be
smooth and even. If a caliper piston is frozen or difficult to
bottom, the caliper requires overhaul or replacement.
RTW35CSH000701
When not entering with a finger, insert a discarded inner brake
pad (2) or block of wood in front of the pistons. Using 2 large
C-clamps (1) installed over the body of the caliper (3) and
against the brake pad or block of wood, slowly bottom the
pistons evenly into the bores.
Insert the dust seal ring into the dust seal.
CAUTION:
Piston made by plastic material.
Don’t must be hit on the piston by hammer etc. and don’t
grasp to face of piston by pliers.


5. Bleeder
Torque Nm(kgfm/Ibin)
9 – 16 (0.9 – 1.6 / 78 - 139)

6. Cap