piston ISUZU TF SERIES 2004 Owner's Manual

5C-54 BRAKES
Important Operations
When disassembling, inspecting or reassembling the master
cylinder assembly, take care not to bring the parts into contact
with mineral oil or dust. Wash the piston cups only with brake
fluid. Do not use gasoline or other mineral-base cleaning
solvents.



6. Ring ; Snap
Remove the snap ring from the cylinder body with pushing in
the primary and secondary pistons.
7. Stop Pin
Remove the stop pin from the cylinder body with pushing in the
primary and secondary pistons.


8. Piston Assembly ; Primary and Spring
9. Piston Assembly ; Secondary and Spring
Don’t remove the spring from the piston.

BRAKES 5C-55
INSPECTION AND REPAIR

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




Cylinder inside face


Piston


Piston cap


Piston cap spacer


Return port

Return spring


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



Return Port
Check the return port for obstructions and if necessary, clean
with a tag wire.
Blow away foreign matter with compressed air.



Primary Piston
After reassembly, push in the primary piston to see that returns
smoothly.
Repeat the test two or three times to see that brake fluid is
forced out from the front and rear outlets.

5C-56 BRAKES
REASSEMBLY



Reassembly Steps
1. Secondary piston
2. Primary piston
3. Cylinder body
4. Grommet
5. Reservoir tank


6. Stop pin
7. Bolt
8. Snap ring
9. Diaphragm
10. Cap




1. Secondary piston
Lubricate the piston cups on the secondary piston assemblies
with brake fluid.
Note :
Be sure to use a new piston.









2. Primary piston
Lubricate the piston cups on the primary piston assemblies
with brake fluid (1) and the rubber grease (2).
Note :
Be sure to use a new piston.

BRAKES 5C-57


3. Cylinder body
Install the secondary piston and the primary piston to the
cylinder body.
Note :
The secondary piston long hole and the cylinder body stop pin
hole must be aligned at installation.



4. Grommet
5. Reservoir tank
6. Stop pin
7. Bolt
1. Install the grommets to the reservoir tank.
Note :
Be sure to use are new grommets.

330R300018












































































2. Press down on the primary piston and install the stop pin
to the cylinder body (the piston long hole must be
aligned with the cylinder body installation hole).
3. Install the reservoir tank to the cylinder body.
4. Tighten the bolts to the specified torque.
Torque N

m (kgf

m/lb

in)
2 - 3 (0.2 - 0.3 / 17 - 26)



8. Snap pin
Press down on the primary piston and install the snap ring to
the cylinder body groove.
Note :
Be sure to use new snap ring.
9. Diaphragm
10. Cap

BRAKES 5C-59
330R300002
Important Operation-Removal
1. Brake pipe
When hurdling, be careful not to spill brake fluid over the
painted surfaces, as damage to the paint finish will result.
2. Master Cylinder Fixing Nut
3. Bracket (only RHD model)
4. Master Cylinder Assembly
NOTE:
When removing the master cylinder from the vacuum booster,
be sure to get rid of the internal negative pressure of the
vacuum booster (by, for instance, disconnecting the vacuum
hose) in advance.
If any negative pressure remains in the vacuum booster, the
piston may possibly come out when the master cylinder is
being removed, letting the brake fluid run out.
While removing the master cylinder, further, do not hold the
piston as it can be easily pulled out.

7C-6 CLUTCH
6VE1/LHD

RTW47CSF000101

6VE1, 4J/RHD

RTW47CSF000401
The master cylinder converts mechanical energy into hydraulic energy.
Depressing the clutch pedal causes the push rod to move against the piston to close the return port.
Clutch fluid is forced out of the master cylinder.
Releasing the clutch pedal causes the return spring to force the piston back to its original position.
The return port is opened and the clutch fluid flows back into the fluid reservoir.
Quickly releasing the clutch pedal will cause the fluid pressure at the return spring side to be lower than the fluid
pressure at the push rod side.
This allows the fluid at the push rod side to quickly flow to the return spring side through a port in the piston head.
This equalizes the pressure at both sides of the piston.

CLUTCH 7C-7
SLAVE CYLINDER
6VE1
A07RS005
4J

C24SE

RTW47CSF000301
The slave cylinder converts hydraulic energy into mechanical energy.
Hydraulic fluid supplied by the master cylinder moves the slave cylinder piston to actuate the shift fork.
The mechanical energy produced by the slave cylinder is directly proportional to the diameters of the master
cylinder and the slave cylinder.
A bleeder screw is provided to bleed the slave cylinder.

CLUTCH 7C-35
SLAVE CYLINDER (4J, C24SE)
DISASSEMBLY



Disassembly Steps


1. Boot
2. Push rod
3. Piston and piston cup


4. Spring
5. Cylinder body




Important Operations
1. Boot
Brake fluid spilled on painted or plastic surfaces will cause
serious damage.
Take care not to spill brake fluid.

7C-36 CLUTCH
INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during
inspection.




Cylinder Body
1. Clean the cylinder body.
2. Check the fluid return port for restrictions and clean it i
f
necessary.



Cylinder Bore and piston Clearance
1. Clean the cylinder body and the piston.
2. Use an inside dial indicator to measure the cylinder bore.
3. Use a micrometer to measure the piston diameter.
4. Calculate the clearance between the cylinder bore and the
piston diameter.
If the clearance exceeds the limit, the entire slave cylinde
r
assembly must be replaced.
Cylinder Bore and Piston Clearance mm(in)
Standard Limit
0.07 (0.0028) 0.15 (0.006)



Piston and Piston Cup
Visually inspect the disassembled piston and piston cup for
excessive wear and damage.
Replace the inner parts with new parts (Repair kit A) shown in
the illustration.

CLUTCH 7C-37
REASSEMBLY



Reassembly Steps


1. Cylinder body
2. Spring


3. Piston and piston cup


4. Push rod
5. Boot







Important Operations
1. Cylinder Body
1) Clean the cylinder body.
2) Apply brake fluid to the cylinder bore.


3. Piston and piston Cup
1) Apply brake fluid to the piston and piston cup.
2) Install the cups to the piston.
Note the installation direction of the piston cups in the
illustration.
3) Install the piston and piston cup to the cylinder body.