brake ISUZU TF SERIES 2004 Workshop Manual

5C-64 BRAKES
MEMO

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

PARKING BRAKE SYSTEM 5D-3







This illustration shows RHD model
LHD model is opposite.
RTW35DLH000101

Legend

(1)
Nut

(2)
Bolt and Washer

(3)
Adjust Nut

(4)
Bolt


(5)
Front Parking Brake Cable

(6)
Clip

(7)
Switch

(8)
Bolt

(9)
Parking Lever Assembly


Removal
1. Remove instrument panel assembly & cross beam
in legend numbers order.

Refer to section 10.
2. Bolts (2)(8) are already removed in step 1.
3. Remove adjust nut (3).
4. Pull out clip (6) and take out front parking brake
cable (5) from parking lever assembly (9).
5. Remove bolts (4) and nut (1) and take out parking
lever assembly (9).
6. Remove switch (7).
Installation
1. Install switch (7).
Torque: 1.5 N




m (0.15 kg




m/13 lb in)
2. Set parking lever assembly (9).
3. Install bolts (4) and nut (1) and tighten them to the
specified torque.
Torque: 15 N





m (1.5 kg





m/11 lb ft)
4. Set front parking brake cable (5) in parking leve
r
assembly (9).
5. Drive clip (6) into the outer cable groove of front
parking brake cable (5) at the outside of parking
lever assembly (9).

5D-4 PARKING BRAKE SYSTEM

6. Drive adjust nut (3) on the front end of front
parking brake cable (5) so that front ends of rea
r
parking brake fit into the rear end (equalizer) of
front cable (5).
7. Install instrument panel assembly & cross beam.

Refer to section 10.
8. Install bolts (2) (8) and tighten them to the
specified torque.
Torque: 15 N




m (1.5 kg




m/11 lb ft)
9. Install all parts removed when removal steps.

Refer to section 10.
10. When a parking cable is replaced, pull parking
brake lever with a force equivalent to operating
force: 490N (50 kg/110 lb), 10 times fo
r
conditioning.
11. Adjust nut (3) so that lever (9) goes through 8

14
notches, when pulled with a operation force o
f
294N (30 kg/66 lb) and check brake for no drag.

PARKING BRAKE SYSTEM 5D-5

Front Parking Brake Cable
Front Parking Brake Cable and Associated Parts (Bench Seat)


750R300003

Legend

(1)
Shift Knob (manual transmission)

(2)
Front Floor Console

(3)
Rear Cover

(4)
Bolt


(5)
Seat Assembly

(6)
Buckle: side seat and Center Seat Belt

(7)
Seat Adjuster

5D-6 PARKING BRAKE SYSTEM





This illustration is based on RHD model.
RTW35DMF000101

Legend

(1)
Adjust Nut

(2)
Clip

(3)
Bolt


(4)
Bolt

(5)
Parking Brake Cable T-end

(6)
Front Parking Brake Cable


Removal
1. Remove seat assembly and seat adjuster.
Refer to section 10.
2. Turn over the carpet so that front parking brake
cable (6) appears.
3. Remove adjust nut (1).
4. Pull out clip (2) and take out front parking brake
cable (6).
5. Remove bolt (3) (4).
6. Disconect parking brake cable T-ends (5) from
front parking brake cable (6).
7. Take out front parking brake cable through the
floor hole.
Installation
1. Apply grease (multipurpose type grease) to the
connecting portion of parking brake cable T-end
(5) and front parking brake equalizer. (arrow mark)
2. Let rear end (equalizer) of front parking brake
cable (6) enter the floor hole and connect it with
parking brake rear cable T-end (5).
3. Set front parking brake cable (6) in the parking
lever assembly.
4. Drive clip (2) into the outer cable groove of front
parking brake cable (6) at the outside of the
parking lever assembly.
5. Install bolt (3)(4) on the floor and tighten them to
the specified torque.
Torque: 15 N




m (1.5 kg




m/11 lb ft)

PARKING BRAKE SYSTEM 5D-7

6. Drive adjust nut (1) on the front end of front
parking brake cable (6) so that parking brake
cable T-end fits into the rear end (equalizer) o
f
front cable (6).
7. Fit the carpet on the floor.
8. Install seat adjuster and seat assembly.

Refer to section 10.
9. Pull parking brake lever with a force equivalent to
operating force: 490N (50 kg/110 lb), 10 times fo
r
conditioning.
10. Adjust nut (1) so that parking brake lever goes
through 8

14 notches, when pulled with a
operation force of 294N (30 kg/66 lb).
11. Check brake for no drag.

5D-8 PARKING BRAKE SYSTEM

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


RTW35DSF000101

Legend

(1)
Rear Floor Console

(2)
Parking Brake Cable T-end

(3)
Adjust Nut


(4)
Switch

(5)
Parking Brake Lever Assembly

(6)
Bolt

(7)
Equalizer


Removal
1. Remove rear floor console (1).

Refer to section 10.
2. Loosen adjust nut (3).
3. Remove bolt (6).
4. Remove switch (4).
5. Disconnect parking brake cable T-end (2) from
parking brake lever assembly (5).
6. Take out parking brake lever assembly (5).

Installation
1. Apply grease (multipurpose type grease) to the
connecting portion of parking brake rear cable T-
end (2) and parking brake lever equalizer (7).
(arrow mark)
2. Connect parking brake rear cable T-end (2) to
equalizer (7).
3. Install switch (4).

4. Tighten the parking brake lever fixing bolt (6) to
the specified torque.
Torque: 15 N




m (1.5 kg




m/11 lb ft)
5. Drive adjust nut (3) on parking brake assembly so
that parking brake cable T-end fits into equalize
r
(7).
6. Install rear floor console (1).
Refer to section 10.
7. Pull parking brake lever with a force equivalent to
operating force: 490 N (50 kg/110 lb), 10 times fo
r
conditioning.
8.
Adjust nut (3) so that parking brake lever goes
through 6

8 notches, when pulled with a operation
force of 294 N (30 kg/66 lb).
9. Check brake for no drag.

PARKING BRAKE SYSTEM 5D-9

Parking Brake Rear Cable
Parking Brake Rear Cable and Associated Parts
RTW35DLF000101

Legend

(1)
Tension Pin

(2)
Shoe Clamp Spring

(3)
Return Spring

(4)
Shoe Assembly with Parking Brake Lever

(5)
Shoe Assembly with Adjuster Lever

(6)
Spring

(7)
Parking Brake Rear Cable


(8)
Nut

(9)
Bolt

(10)
Nut

(11)
T-end

(12)
Outer Cable Retainer

(13)
Equalizer

(14)
Adjuster Lever Clip