parking brake ISUZU TF SERIES 2004 Workshop Manual
[x] Cancel search | Manufacturer: ISUZU, Model Year: 2004, Model line: TF SERIES, Model: ISUZU TF SERIES 2004Pages: 4264, PDF Size: 72.63 MB
Page 155 of 4264

PROPELLER SHAFT 4A-19
Front Propeller Shaft
Removal and Installation
RTW34AMF000301
Legend
(1) Bolt, Nut and Washer (Front Axle Side)
(2) Front Propeller Shaft
(3) Nut and Washer (Transfer Side)
401RS020
Removal
1. Jack up the vehicle and support it on the chassis stands.
2. Gear shift lever should be placed in neutral position and
parking brake released.
3. Remove the exhaust and transfer protectors.
NOTE:
Apply alignment marks on the flange at the front propeller shaft
both front and rear side.
4. Remove bolt, nut and washer (Front axle side).
5. Remove bolt, nut and washer (Transfer side).
6. Remove front propeller shaft.
Page 175 of 4264

REAR AXLE 4B-11
305R30000
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 Cable
8.
Adjuster
9.
Parking Brake Lever
10.
Adjuster Spring
11.
Adjuster Lever
12.
Wheel Cylinder
13.
Back plate
4.
Remove tension pin and shoe clamp spring.
5.
Remove return spring.
6.
Remove shoe assembly with parking brake lever.
7. Remove shoe assembly with adjuster lever and
spring.
8.
Remove parking brake inner cable from parking
brake lever.
9.
Use offset box wrench to compress locking lugs
on the cable, then remove parking brake outer
cable from back plate.
311RS012
Page 180 of 4264

4B-16 REAR AXLE
8.
Certainly install new snap ring, use snap ring pliers.
When transform or damage, replace new one.
RTW34BMH000101
Legend
1.
Snap ring
2.
Crevice
3.
Sensor rotor (with ABS)
Spacer (without ABS)
9.
Insert a shim of sufficient thickness between snap
ring and end of sensor rotor (or spacer).
Standard
0
0.2 mm (0
0.008 in)
Crevice is measured using thickness gauge, and
when crevice exceeds 0.2 (mm), it adjusts so that
is may become 0.2 (mm) or less using shim.
Shim Pats No.
Thickness
1 9-41519110-
0.18 mm (0.0071 in)
2 8-97130387-
0.50 mm (0.0197 in)
Crevice
No. of shim
Total
Mm (in)
1 2
mm (in)
1.0(0.0394)
2
1.00(0.0394)
0.9(0.0354)
2
1
0.86(0.0339)
0.8(0.0315)
1
1
0.68(0.0268)
0.7(0.0276)
1
1
0.68(0.0268)
0.6(0.0236)
1
0.50(0.0197)
0.5(0.0197)
1
0.50(0.0197)
0.4(0.0158)
2
0.36(0.0142)
0.3(0.0118)
1
0.18(0.0071)
0.2(0.0079)
1
0.18(0.0071)
10. Install axle shaft assembly in rear axle case
assembly.
Note:
When inserting an axle shaft, it inserts so that an
oil seal may not be damaged.
11. Install and tighten bearing holder fixing nut to the
specified torque.
Torque : 84 N
m (8.6 kg
m/62 lb
ft)
12. Install wheel cylinder and tighten the bolt to the
specified torque.
Torque : 9 N
m (0.9 kg
m/78 lb
ft)
13. Install parking brake outer cable in back plate and
inner cable in parking brake lever.
Page 181 of 4264

REAR AXLE 4B-17
14.
Install shoe assembly with adjuster lever, shoe
assembly with parking brake lever and spring.
15.
Install return spring.
16.
Install shoe clamp spring and tension pin.
305R300001
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 Cable
8.
Adjuster
9.
Parking Brake Lever
10.
Adjuster Spring
11.
Adjuster Lever
12.
Wheel Cylinder
13.
Back plate
Page 336 of 4264

5A-20 BRAKE CONTROL SYSTEM
Electronic Brake-force Distribution (EBD) System
ABS has the EBD function. EBD is a function which
controls braking force distribution of a front wheel and a
rear wheel, and makes brake fluid pressure of a rear
wheel the optimal. If the rate of a slip of a rear wheel
becomes large more than fixed compared with a front
wheel about the rate of a slip in order to perform
braking force distribution of a front wheel and a rear
wheel, the brake fluid pressure of a rear wheel will be
controlled. EBD enables it to always utilize the braking
power of a rear wheel for the maximum according to
the load change concerning the back axis by vehicles
loading states (No luggage, loading, etc.), deceleration,
etc. Brake fluid pressure control to a rear wheel is
performed by the EBD function which used the ABS
function without the mechanical proportioning valve.
C05L300016
Brake Pedal Travel
Vehicles equipped with the Anti-lock Brake System may
be stopped by applying normal force to the brake pedal.
Although there is no need to push the pedal beyond the
point where it stops or holds the vehicle, by applying
more force the pedal will continue to travel toward the
floor.
This extra brake pedal travel is normal.
Acronyms and Abbreviations
Several acronyms and abbreviations are commonly
used throughout this section:
ABS
Anti-lock Brake System
CKT
Circuit
DLC
Data Link Connector
EBD
Electronic Brake-force Distribution
EHCU
Electronic Hydraulic Control Unit
FL
Front Left
FR
Front Right
GEN
Generator
H/U
Hydraulic Unit
MV
Millivolts
RR
Rear
RPS
Revolution per Second
VDC
DC Volts
VAC
AC Volts
W/L
Warning Lamp
WSS
Wheel Speed Sensor
General Diagnosis
General Information
ABS troubles can be classified into two types, those
which can be detected by the ABS warning lamp and
those which can be detected as a vehicle abnormality
by the driver.
In either case, locate the fault in accordance with the
“BASIC DIAGNOSTIC FLOWCHART” and repair.
Please refer to Section 5C for the diagnosis of
mechanical troubles such as brake noise, brake judder
(brake pedal or vehicle vibration felt when braking),
uneven braking, and parking brake trouble.
ABS Service Precautions
Required Tools and Items:
Box Wrench
Brake Fluid
Special Tool
Some diagnosis procedures in this section require the
installation of a special tool.
5-8840-0366-0 High Impedance Multimeter
When circuit measurements are requested, use a
circuit tester with high impedance.
Page 338 of 4264

5A-22 BRAKE CONTROL SYSTEM
“ABS” Warning Lamp
When ABS and trouble occurs to actuate “ABS”
warning lamp, the trouble code corresponding to the
trouble is stored in the EHCU. Only ordinary brake is
available with ABS being unactuated. Even when
“ABS” warning lamp is actuated, if the starter switch is
set ON after setting it OFF once, the EHCU checks up
on the entire system and, if there is no abnormality,
judges ABS to work currently and the warning lamp is lit
normally even though the trouble code is stored.
NOTE: Illumination of the “ABS” warning lamp indicates
that anti-lock braking is no longer available. Power
assisted braking without anti-lock control is still
available.
Normal Operation
“ABS ” Warning Lamp
When the ignition is first moved from “OFF” to “RUN”,
the amber “ABS” warning lamp will turn “ON”. The
“ABS” warning lamp will turn “ON” during engine
starting and will usually stay “ON” for approximately
three seconds after the ignition switch is returned to the
“ON” position. The warning lamp should remain “OFF”
at all other times.
Brake (EBD) Warning Lamp
825L300001
Vehicles equipped with the EBD (Electronic Brake-force
Distribution) System have an have “Brake” warning
lamp in the instrument panel.
If ABS warning lamp and Brake warning lamp are turn
"ON", then EBD is failed. ( Parking brake switch is
"OFF")
In the following conditions, EBD warning lamp is "ON".
Starter switch is "ON", engine "OFF".
( Parking brake switch is "OFF")
If engine is started, then EBD warning lamp is "OFF".
( Parking brake switch is "OFF")
Page 344 of 4264

5A-28 BRAKE CONTROL SYSTEM
Isolation Valve Test
Purpose: The purpose of this test is to detect brake
pipe and valve line harness wire for wrong connections
and valve trouble.
This test will help you confirm the result of your repair
service including the removal/reinstallation of brake
pipe, valve line harness and valve.
Test conditions: The ignition key is in the “ON” position
with the four wheels lifted up. The brake pedal is
stepped on, released and stepped on again with the
parking brake released.
Test procedure:
1. Connect Tech 2 with the vehicle, and select
Actuaor Test from the menus.
2. Select a Solenoid Valve Test Menu from the
Actuaor Test Menus.
060L300002
3. Select Isolation Valve from the Valve Select Menus.
4. Step on the brake pedal.
5. Release the brake pedal.
6. Make sure that the Isolation Valve “ON” aimed at by
Tech 2 and the wheel locked position are the same.
If different, check brake pipe, valve line harness
wiring and H/UNIT. Repair is needed if abnormality
is found.
7. Conduct Step 2 through Step 5 above on all the
four wheels.
060L300002
CAUTION: When conducting this test, please
observe the following cautions.
1. Do not start the engine.
2. Lift up the vehicle at a level floor.
Secure a clearance from the floor surface
enough to allow the lifted tire to rotate.
3. Maintain the lift up.
4. Wipe the floor surface to remove water and oil
so that the surface may become unslippery.
5. Do not load the vehicle.
When lifting up the vehicle, be sure to
observe the lifting up points. Refer to
vehicle lifting points in 0A section.
Page 345 of 4264

BRAKE CONTROL SYSTEM 5A-29
Dump Valve Test
Purpose: The purpose of this test is to detect brake
pipe and valve line harness wire for wrong connections
and valve trouble.
This test will help you confirm the result of your repai
r
service including the removal/reinstallation of brake
pipe, valve line harness and valve.
Test conditions: The ignition key is in the “ON” position
with the four wheels lifted up. The brake pedal is
stepped on, released and stepped on again with the
parking brake released.
Test procedure:
1. Connect Tech 2 with the vehicle, and select
Actuator Test Function from the menus.
2. Select a Solenoid Valve Test Menu from the
Actuator Test Menus.
060L300002
3. Select Dump Valve from the Valve Select Meuns.
4. Step on the brake pedal.
5. Make sure that the Dump Valve “ON” aimed at by
Tech 2 and the wheel released position are the
same. If different, check brake pipe, valve line
harness wiring and H/UNIT. Repair is needed if
abnormality is found.
6. Conduct Step 2 through Step 5 above on all the
four wheels.
060L300002
CAUTION: When conducting this test, please
observe the following cautions.
1. Do not start the engine.
2. Lift up the vehicle at a level floor.
Secure a clearance from the floor surface
enough to allow the lifted tire to rotate.
3. Maintain the lift up.
4. Wipe the floor surface to remove water and oil
so that the surface may become unslippery.
5. Do not load the vehicle.
When lifting up the vehicle, be sure to
observe the lifting up points. Refer to
vehicle lifting points in 0A section.
Page 451 of 4264

BRAKES 5C-25
Filling Master Cylinder Reservoir
CAUTION :
Use only specified brake fluid. Do not use any fluid which
contains a petroleum base. Do not use a container which
has been used for petroleum based fluids or a container
which is wet with water. Petroleum based fluid will cause
swelling and distortion of rubber parts in the hydraulic
brake system. Water mixed with brake fluid lowers the
fluid boiling point. Keep all fluid containers capped to
prevent contamination.
Always fill the master cylinder reservoir when the engine
is cold.
Never allow the brake fluid to come in contact with the
painted surfaces.
The master cylinder reservoir must be kept properly filled
to ensure adequate reserve and to prevent air and
moisture from entering the hydraulic system. However,
because of expansion due to heat absorbed from the
brakes and the engine, the reservoir must not be
overfilled. Thoroughly clean reservoir cap before removal
to avoid getting dirt into reservoir. Add fluid as required to
bring level to the “MAX” mark on the reservoir tank. Use
“DOT 3” Hydraulic Brake Fluid.
Leakage of Brake Fluid
With engine idling, set shift lever in the neutral position and
continue to depress brake pedal at a constant pedal
application force.
Should the pedal stroke become deeper gradually, leakage
from the hydraulic pressure system is possible.
Make sure by visual check that there is no leak.
BLEEDING OF THE BRAKE HYDRAULIC
CIRCUIT
If air enters the bake lines, it will cause poor brake action.
Therefore, bleeding should be performed if the brakes have
been used with the level of brake fluid in the reservoir
excessively low or if brake pipes have been disconnected in
the course of brake servicing.
Bleeding operation calls for co-operative action of 2 persons.
Set the parking brake firmly while bleeding.
Perform bleeding operation with ENGINE RUNNING, to
prevent damage to push rod seal.
Make sure exhaust is suitably ventilated.
Bleed the hydraulic system with the fluid reservoir filled to
the specified level.
Bleed the system starting with the rear wheel cylinde
r
farthest from the master cylinder.
Page 452 of 4264

5C-26 BRAKES
A bleeding operation is necessary to remove air from the
hydraulic brake system whenever air is introduced into the
hydraulic system. It may be necessary to bleed the hydraulic
system at all four brakes if air has been introduced through a
low fluid level or by disconnecting brake pipes at the master
cylinder. If a brake pipe is disconnected at one wheel, only that
wheel cylinder/caliper needs to be bled. If the pipes are
disconnected at any fitting located between the master cylinder
and brakes, then the brake system served by the disconnected
pipe must be bled.
1. Set the parking brake completely, then start the engine.
NOTE :
The vacuum booster will be damaged if the bleeding operation
is performed with the engine off.
2. Remove the master cylinder reservoir cap.
3. Fill the master cylinder reservoir with brake fluid. Keep the
reservoir at least half full during the air bleeding operation
4. Always use new brake fluid for replenishment.
5. In replenishing rake fluid, take care that air bubbles do no
t
enter the brake fluid.
When the master cylinder is replaced or overhauled, firs
t
bleed the air from the master cylinder, then from each
wheel cylinder and caliper following the procedures
described below.
Bleeding the Master Cylinder
6. Disconnect the rear wheel brake pipe (1) from the master
cylinder.
Check the fluid level and replenish as necessary. If
replenished, leave the system for at least one minute.
7. Depress the brake pedal slowly once and hold it depressed.
8. Completely seal the delivery port of the master cylinder with
your finger, where the pipe was disconnected then release
the brake pedal slowly.
9. Release your finger from the delivery port when the brake
pedal returns completely.
10. Repeat steps 7 through 9 until the brake fluid comes out o
f
the delivery port during step 7.
NOTE : Do not allow the fluid level in the reservoir to go below
the half-way mark.
11. Reconnect the brake pipe (1) to the master cylinder and
tighten the pipe.
12. Depress the brake pedal slowly once and hold it depressed.
13. Loosen the rear wheel brake pipe (1) at the master cylinder.
14. Retighten the brake pipe, then release the brake pedal
slowly.