brakes ISUZU TF SERIES 2004 Repair Manual

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

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)

BRAKES 5C-51
BRAKE CONTROL
REMOVAL AND INSTALLATION

BRAKE PEDAL ASSEMBLY

This illustration shows RHD model
LHD model is opposite.
310R300001

Removal Steps
1. Nut ; fulcrum pin
2. Pin ; fulcrum, pedal to bracket
3. Pedal arm
4. Return spring
5. Pedal pad

Installation steps
To install, follow the removal procedure in
reverse order.
Before installation, apply grease to the entire
circumference of the fulcrum pin (2).
Refer to "SERVICING" in this section for
adjustment procedure of brake pedal.

5C-52 BRAKES
MASTER CYLINDER
REMOVAL AND INSTALLATION

MASTER CYLINDER ASSEMBLY



This illustration is based on RHD model.
330R300008

Removal Steps

1. Brake line
2. Nut ; master cylinder to vacuum booster
3. Master cylinder assembly

Installation Steps
3. Master cylinder assembly

2. Nut ; master cylinder to vacuum booster

1. Brake line




Important Operation - Removal
1. Brake Line
Be very careful not to spill brake fluid on the painted surface.
Damage to the painted surface will result.








Important Operation - Installation
2. Nut ; Master Cylinder to Vacuum Booster
Torque N
m (kgf
m/lb
ft)
12 – 18 (1.2 – 1.8 / 9 – 13)

1. Brake Line
Torque N

m (kgf

m/lb

ft)
13 – 19 (1.3 – 1.9 / 9 – 14)