brakes ISUZU TF SERIES 2004 Repair Manual

BRAKES 5C-53
DISASSEMBLY

RTW35CMF000401

Disassembly Steps
1. Cap
2. Diaphragm
3. Bolt
4. Resever tank
5. Grommet




6. Snap ring

7. Stop pin

8. Primary piston

9. Secondary piston
10. Cylinder body


Note :
 Be sure to replace the designated with new ones.
 Wash the disassembled parts in clean brake fluid.
 Use compressed air to clean the ports.
 Do not allow dirt and dust to contaminate the disassembled
parts.

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

5C-58 BRAKES
VACUUM BOOSTER
REMOVAL AND INSTALLATION



This illustration is based on RHD model.
RTW35CMF000501

Removal Steps

1. Brake pipe

2. Master cylinder fixing nut

3. Bracket (only RHD model)

4. Master cylinder assembly
5. Vacuum hose
6. Snap pin
7. Vacuum booster fixing nut
8. Vacuum booster assembly

Installation Steps


8. Vacuum booster assembly

7. Vacuum booster fixing nut

6. Snap pin

5. Vacuum hose
4. Master cylinder assembly
3. Bracket (only RHD model)
2. Master cylinder fixing nut
1. Brake pipe

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.

5C-60 BRAKES
Inspection and Repair
Vacuum Hose (The built in check valve)
360R300002


1) Inspect the check valve (2), which is installed inside the
vacuum hose.
2) Blow air into the hose from the booster side as shown in
the illustration. The air should pass freely through the
hose.
3) Blow air into the hose from the engine side. The check
valve should close to block the passage of air.
The vacuum hose and built-in check valve must be
replaced as a set if either is found to be defective.

Important Operation-Installation
8. Vacuum Booster Assembly
7. Vacuum Booster Fixing Nut
6. Snap Pin
1) Perform vacuum booster and vacuum booster push rod
adjustment.
Note :
When replacing either the master cylinder or vacuum booster,
be sure to measure push rod, and adjust if required.

RTW35CSH000901

2) Measure the dimension (B) of master cylinder.


3) Apply negative pressure by means of vacuum pump so
that the pressure in the vacuum booster becomes
GASOLINE ENGINE: 66.7 kPa (500 mm Hg) or DIESEL
ENGINE 93.3 kPa (700 mm Hg).
Note :
Be sure to apply NEGATIVE pressure after installing a push
rod gauge on the vacuum booster.

BRAKES 5C-61


















4) Measure dimension (A)

RTW35CSH000801







5) Calculate the gap (B-A) when assembling the master
cylinder and vacuum booster.

GAP mm (in
)
0 
0.4 (0 
0.0157)



6) If dimension (A) is out of the standard range, adjust the
push rod.

Loosen the push rod lock nut (1) on the vacuum
booster.

Set the clevis (2).

Use the adjuster (3) to adjust the length of the
protruding portion of the push rod.

Vacuum (negative) pressure should be GASOLINE
ENGINE: 66.7 kPa (500mm Hg) or DIESEL
ENGINE: 93.3 kPa (700mm Hg) after adjustment.

Tighten the push rod lock nut to the specified torque.







Torque N

m(kgf

m/lb

ft)
18 – 25 (1.8 – 2.5 / 13 – 18)

7) Install the vacuum booster assembly to the dash panel
and pedal mounting bracket.
Torque N

m(kgf

m/lb

ft)
18 – 24 (1.8 – 2.4 / 13 – 17)

5C-62 BRAKES
360r300003
5. Vacuum Hose
The check valve (2) is built-in to the vacuum hose.
When installing the vacuum hose make sure that the arrow on
the hose is facing the engine (1).
Note :

Do not apply oil to the vacuum hose.



Installation direction is very important. The booster will no
t
operate if the vacuum hose is installed in the wrong
direction.


4JA1-T/4JA1-TC/4JH1-TC LHD model (with 2nd Battery)


RTW45CLF000101