wheel ISUZU TF SERIES 2004 Workshop Manual

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.)

5C-44 BRAKES
REAR DRUM BRAKE ASSEMBLY
DISASSEMBLY

First, disassemble the brake drum. Then disassemble the rear brake assembly.
Refer to the “REAR AXLE ” section for the brake drum disassembly procedure.

RTW35CMF000201

MAJOR COMPONENTS
Disassembly Steps

1. Spring ; adjuster
2. Ring ; Adjuster lever
3. Lever ; adjuster

4. Spring ; Shoe hold
5. Pin ; Shoe hold

6. Spring ; Shoe to shoe, lower
7. Adjuster assembly
8. Spring ; shoe to shoe, upper
9. Shoe ; leading

10. Shoe ; trailing
11. Spring ; lever return
12. Retainer
13. Washer ; lever
14. Lever ; parking
15. Bolt ; wheel cylinder
16. Wheel cylinder assembly
17. Cover
18. Back plate

MINOR COMPONENTS
Disassembly Steps
Wheel Cylinder Assembly (14)

19. Piston
20. Cup
21. Boot ; piston

22. Return spring
23. Bleeder
24. Cap ; bleeder

BRAKES 5C-45

P1010008


Important Operations
4. Spring ; shoe hold
Push the shoe hold spring toward the brake shoe and hold it.
Rotate the spring to remove it from the shoe hold pin.


6. Spring ; shoe to shoe, lower
Slide the brake shoes and lower spring toward the ground.
Remove the lower spring.


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





Brake drum


Back plate


Brake lining


Wheel cylinder body


Piston

Piston cup

Return spring



Visual check
Inspect the following parts for wear scuffs, scratches,
corrosion, stains, deterioration, or other abnormal conditions.





Thickness of the Brake Lining
Thickness mm(in)
standard (T) Limit (t)
4

2 5.0 (0.197) 1.0 (0.039)
4

2 HIGH RIDE
4

4 5.0 (0.197) 1.0 (0.039)

5C-46 BRAKES



Clean wheel Cylinder Parts
Always use clean brake fluid to clean wheel cylinder parts.
Note:
Do not use mineral-vase cleaning solvents such as
gasoline, kerosene, acetone, paint thinner, or carbon
tetrachloride.



Piston Cups
Inspect the piston cups for wear, distortion, fatigue, fatigue or
other abnormal conditions.



Measuring the Brake Drum
mm(in)
Standard Limit
Inside diameter 254 (10.000) 255.5 (10.059)
Run out 0.08 (0.003) 0.15 (0.006)
Inside diameter 295 (11.614) 296.5 (11.673)TFR (HIGH RIDE)
TFS Run out 0.08 (0.003) 0.15(0.006)
TFR

BRAKES 5C-47
REASSEMBLY

RTW35CMF000301

MINOR COMPONENTS
Reassembly Steps
Wheel cylinder Assembly (7)

1. Piston assembly
2. Cup ; piston
3. Return spring



4. Boot ; piston

5. Bleeder
6. Cap ; bleeder

MAJOR COMPONENTS
Reassembly Steps

7. Back plate
8. Cover

9. Wheel cylinder assembly

10. Bolt ; wheel cylinder

11. Shoe ; leading

12. Lever ; parking

13. Washer ; lever

14. Retainer
15. Spring ; lever return



16. Shoe ; trailing

17. Spring ; shoe to shoe, upper

18. Adjust assembly
19. Spring ; shoe to shoe ; lower

20. Lever ; adjuster

21. Ring ; Adjuster lever
22. Spring ; shoe hold

23. Pin ; shoe hold

24. spring ; adjuster

5C-48 BRAKES



Important Operations
Note :


Wash the disassembled parts in clean brake fluid.


Use compressed air to clean the ports.


Protect the disassembled part surfaces from dust and othe
r
foreign material contamination.


Before reassembly, check the part surfaces for dust and
other foreign material contamination.


Be sure to replace the designated parts with new ones.

4. Piston Assembly
Install new piston cups on each piston so that the flared end of
the cups are turned to the inboard side of the pistons.
Attach the return spring and the boot to the piston.
Be sure to use new piston cup and boot.




Apply brake fluid to the piston and the inner face of the
boots.


Note the direction of piston cup.



5. Bleeder ; Wheel Cylinder
Torque Nm(kgfm/Ibin)
6 - 8 (0.6 – 0.8 / 52 - 69)



9. Wheel Cylinder Assembly
10. Bolt ; Wheel cylinder
Torque N
m(kgf
m/Ib
ft)
7 - 11 (0.7 – 1.1 / 61 - 95)

BRAKES 5C-49
308R300008







11. Shoe ; leading

Be sure to use new spring; shoe hold.
12. Lever ; parking
13. Washer ; lever
14. Retainer
Install the lever, the washer and the retainer to the leading
brake shoe.



Apply grease to the sliding surfaces of the lever and
brake shoe.

Be sure to use new retainer and washer.
305R300009



















16. Shoe ; trailing


Be sure to use new spring; shoe hold.
17. Spring ; shoe to shoe, upper
18. Adjuster assembly
1. Apply grease to each of the parts shown in the
illustration before installing the brake shoe.

Lever; adjuster-shoe

Adjuster-shoe



2. Clean the adjuster bolt (5) and the adjuster rods (1) (4).
Apply grease to the threaded portion of the adjuster bolt.
3. Install the adjuster rod to the adjuster bolt.
4.
Apply grease to the adjuster asm ends (2) (3). Set the
spring ; upper to the adjuster asm, then install them to
the brake shoe.

305R300010











5. Before setting the brake shoes, apply grease to the back
plate portions (1) contacting the brake shoe edge as
shown in the illustration.
6.
Apply grease to the wheel cylinder parts contacting the
brake shoe (2).
7. Install the brake shoe.
Note :


Be careful not to damage the wheel cylinder dust cover.


Do not allow the wheel cylinder piston to fly free.

5C-50 BRAKES












20. Lever ; adjuster
21. Ring ; Adjuster lever


Apply grease to the lever ; adjuster sliding surface.
Install the lever ; adjuster and the ring to the shoe ;
trailing.


Be sure to use new ring.

P1010008B


23. Pin ; shoe hold
24. Spring ; shoe hold

Install the brake drum.


Install the rear wheel.


If the wheel cylinder has been removed, the brake
system must be bled.


Pump the brake pedal 10 times. Check that there is little
or no stroke length variation as the pedal is pumped.


Adjust the lining clearance.




Brake Line
Torque N
m(kgf
m/Ib
ft)
13 - 19 (1.3 - 1.9 / 9 - 14)

PARKING BRAKE SYSTEM 5D-1

SECTION 5D
BRAKES
PARKING BRAKE SYSTEM
CONTENTS

Service Precaution .......................................... 5D-1
Service Precaution ....................................... 5D-1
General Description ...................................... 5D-1
Parking Brake Lever ........................................ 5D-2
Parking Brake Lever Assembly and
Associated Parts (Bench Seat) .................. 5D-2
Removal ....................................................... 5D-3
Installation............................................................
5D-3
Front Parking Brake Cable....................................
5D-5
Front Parking Brake Cable and Associated
Parts (Bench Seat).........................................
5D-5
Removal...............................................................
5D-6
Installation............................................................
5D-6
Parking Brake Lever...............................................
5D-8
Parking Brake Lever Assembly and Associated
Parts (Buckle Seat)....................................... 5D-8
Removal ....................................................... 5D-8
Installation .................................................... 5D-8
Parking Brake Rear Cable ............................... 5D-9
Parking Brake Rear Cable and Associated
Parts ............................................................ 5D-9
Removal ....................................................... 5D-10
Installation .................................................... 5D-10
Inspection and Repair ................................... 5D-11
Parking Brake Adjustment ............................ 5D-11
Main Data and Specifications........................... 5D-12
Troubleshooting ............................................ 5D-13


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, REFE
R
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, o
r
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/leve
r
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 the "ON" position, the brake warning
light illuminates. The rear wheel parking brake is a
leading-trailing brake (mechanical inside expansion
type) built in the rear drum brake. Parking brake
adjustment is made through the adjusting hole (bored
through back plate). Parking brake lever stroke should
be adjusted to 8

14 notches with 30kg (bench seat) o
r
6

8 notches with 30kg (bucket seat). Refer to “Parking
Brake Adjustment" in this section.

5D-2 PARKING BRAKE SYSTEM

Parking Brake Lever
Parking Brake Lever Assembly and Associated Parts (Bench Seat)



This illustration is based on RHD model.
740R300010

Legend

(1)
Front Console Assembly

(2)
Glove Box

(3)
Instrument Panel Driver Lower Cover Assembly

(4)
Driver Knee Bolster Assembly

(5)
Driver Air Bag


(6)
Steering Wheel/Steering Cowl

(7)
Meter Cluster Assembly

(8)
Dash Side Trim Cover

(9)
Front Piller Trim Cover

(10)
Instrument Panel Assembly & Cross Beam