brake rotor ISUZU TF SERIES 2004 Owner's Guide

5B -14 ANTI-LOCK BRAKE SYSTEM

411R300007
Legend


1.
Metal Bar


2.
Sensor Rotor

Inspection and Repair
Make all necessary adjustments, repairs or part
replacement.


Check damage or powdered iron sticking to the
sensor rotor.


Check play in the sensor rotor.


Check a broken tooth or indentation in the senso
r
rotor.

Installation
1. Set a new sensor rotor.
2. Install the new sensor rotor in the hub, using installe
r
5-8840-2789-0 and grip 5-8840-0007-0.
NOTE: Sensor rotor is surely using a new article.

ANTI-LOCK BRAKE SYSTEM 5B-15

411R300006
Legend


1.
Hub and Disc

2.
Sensor Rotor


3.
Press

3.
Measure the gap “A” at 4 points at intervals of 90
(degrees).

Confirm that the gap “A” should be within the
specified range.
Range
Type A
4


2 7.0 
7.4 mm (0.276 
0.291 in)
4


4,
4


2 High Ride 7.2
 7.6 mm (0.283
 0.299 in)


411R300016
4. Install the hub and disc assembly. (Refer to the
section Front wheel Drive).

5B -16 ANTI-LOCK BRAKE SYSTEM

Rear Speed Sensor Rotor
Rear Sensor Rotor and Associated Parts
420R300007
Legend


1.
Axle Shaft Assembly with Brake

2.
Sensor Rotor


3.
Front

Removal
1. Remove the axle shaft assembly with brake (1).
(Refer to the section Rear Axle)

ANTI-LOCK BRAKE SYSTEM 5B-17

A03R300003
Legend


1.
Bench Press Fitting

2.
Steel Plate (25-30 mm thickness)


3.
Axle Shaft

4.
Sensor Rotor

Inspection and Repair
Make all necessary adjustments, repairs or part
replacement.


Check damage or powdered iron sticking to the
sensor rotor.


Check play in the sensor rotor.


Check a broken tooth or indentation in the senso
r
rotor.
NOTE: If replacement is required remove the sensor
rotor from the axle shaft assembly with brake. (Refer to
the section Rear Axle).


Discard the used sensor rotor.

(Snapring, Oil seal and Bearing)

Installation
1. Install the sensor rotor and assemble it into the axle
shaft assembly with back plate. (Refer to the section
Rear Axle)

5B -18 ANTI-LOCK BRAKE SYSTEM

420R300005
Legend


1.
Axle Shaft

2.
Oil Seal

3.
Bolt


4.
Back Plate

5.
Sensor Rotor

6.
Double Taper Roller Bearing

2. Install the axle shaft assembly with brake in the rea
r
axle. (Refer to the section Rear Axle).

5B -20 ANTI-LOCK BRAKE SYSTEM

Special Tools

ILLUSTRATION PART NO.
PART NAME
ILLUSTRATION
PART NO.
PART NAME

5–8840–2789–0
Installer ; Sensor rotor,
front hub 9-8522-1271-0

Setting Tool
5-8840-0007-0

Grip

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.)

UNIT REPAIR (AW30–40LE) 7A4–7
Major Components (2)
Major Componets (2) and Associated Parts
RT W37 A LF00 0801
E nd O FCallo ut
Legend
(1) Converter housing
(2) Oil pan
(3) Oil strainer assembly
(4) Valve body
(5) Check valve, spring
(6) Spring
(7) Accumulator piston (B–2)
(8) Accumulator piston (C–2)(9) Accumulator piston (B–0)
(10) Accumulator piston (C–0)
(11) Second brake drum gasket
(12) Solenoid wiring
(13) Snap ring, rotor, key (4
4)
(14) Snap ring, speedometer sensor drive gear, ball
(4
2)
(15) Spacer, rotor, key, snap ring (4
2)

7A4–10 UNIT REPAIR (AW30–40LE)
8. Remove the accumulator piston (B–2).
9. Remove the accumulator piston (C–2).
Remove accumulator pistons and springs from
transmission case.
24 0RY 0 001 0
10. Applying compressed air to the oil hole, remove the
B–0 accumulator piston and spring.
24 0RY 0 0011
11. Remove the C–0 accumulator piston.
24 0RY 0 0012
12. Remove the second brake drum gasket.
13. Remove the solenoid wiring.
Turn over transmission, remove the solenoid
wiring stopper plate from the case.
Pull the wiring out of the transmission case.
14. Remove the snap ring, rotor and key (4
4).
Remove the snap ring from the output shaft.
Remove the rotor and key.
2 47R20 0002
15. Remove the snap ring, speedometer sensor drive
gear and ball (4
2).
Remove the snap ring from the output shaft.
Remove the speedometer sensor drive gear, and
ball.

7A4-84 UNIT REPAIR (JR405E)

SERVICE STANDARD
Name BESCO ATF II or ATF III ATF
Quantity L 9.2 – 9.6
Seal ring clearance mm (in) 0.10 – 0.25 (0.0039 – 0.0098)
Housing and inner rotor side clearance mm (in) 0.02 – 0.04 (0.0008 – 0.0016)
Oil pump
Outer rotor and crescent clearance mm (in) 0.02 – 0.15 (0.0008 – 0.0059)
Number of drive plate / driven plate 7/7
Standard mm (in) 2.0 (0.079)Drive plate facing thickness
Limit mm (in) 1.8 (0.071)
Retaining plate and snap ring clearance mm (in) 0.9 – 1.3 (0.035 – 0.051)
3.8 (0.150)
4.0 (0.157)
4.2 (0.165)
4.4 (0.173)
4.6 (0.181)
Available low clutch retaining plate thickness mm (in)
4.8 (0.189)
Number of coil 9.9
Outside diameter mm (in) 9.7 (0.382)
Free length mm (in) 36.4 (1.433)
Low clutch
Return spring
Linear diameter mm (in) 1.2 (0.047)
Number of drive plate / driven plate 5/5
Standard mm (in) 2.0 (0.079)Drive plate facing thickness
Limit mm (in) 1.8 (0.071)
Retaining plate and snap ring clearance mm (in) 1.2 – 1.6 (0.047 – 0.063)
4.6 (0.181)
4.8 (0.189)
5.0 (0.197)
5.2 (0.205)
Available high clutch retaining plate thickness mm (in)
5.4 (0.213)
Number of coil 10.2
Outside diameter mm (in) 8.0 (0.315)
Free length mm (in) 27.1 (1.067)
High clutch
Return spring
Linear diameter mm (in) 1.1 (0.043)
Number of drive plate / driven plate 2/2
Standard mm (in) 2.0 (0.079)Drive plate facing thickness
Limit mm (in) 1.8 (0.071)
Retaining plate and snap ring clearance mm (in) 0.6 – 0.9 (0.0236 – 0.035)
4.8 (0.189)
5.0 (0.197)
5.2 (0.205)
Reverse clutch
Available reverse clutch retaining plate thickness mm (in)
5.4 (0.213)
Low one-way
clutch Seal ring clearance mm (in) 0.10 – 0.25 (0.0039 – 0.0098)
Number of drive plate / driven plate 6/6
Standard mm (in) 2.0 (0.079)Drive plate facing thickness
Limit mm (in) 1.8 (0.071)
Retaining plate and snap ring clearance mm (in) 0.7 – 1.1 (0.028 – 0.043)
5.2 (0.205)
5.4 (0.213)
5.6 (0.220)
5.8 (0.228)
Low & reverse
brake
Available low & reverse brake retaining plate
thickness mm (in)
6.0 (0.236)