air condition ISUZU TFS SERIES 1997 User Guide

BRAKES 5-35
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 Minimum
thickness after
refinishingReplacement
thickness
(Discard)
22.0(0.866) 20.97(0.826) 20.6(0.811)
Run out
Limit mm(in)
0.13 (0.005)
Before inspection, adjust the wheel bearing correctly.
Using a dial gauge, measure the run out at the center of disc
pad contact surface.
Parallelism (Total circumferential thickness variation)
Limit mm(in)
0.15 (0.0006)
Contact surface must be within 0.015 mm at the circumference
of 203 mm dia. Circle.

5-40 BRAKES
Important Operations
3. Return Spring ; Lower
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
W heel 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)
TFR 5.0 (0.197) 1.0 (0.039)
TFS 4.0 (0.157) 1.9 (0.039)
Inspection of the Return Spring
Free length
mm(in.)Set length
mm(in.)Set load
kg (Ibs.)
Holding spring 15.0 (0.591) 11.2 (0.441)10.01.0
(22.3
2.2)
W heel cylinder
spring37.4 (1.472) 8.0 (0.315)1.00.1
(2.2
0.2)

BRAKES 5-49
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.
Master Cylinder Bore Diameter
Standard mm(in)
23.81 (0.938)
Clearance between the Master Cylinder
and the Piston
Measure the outer diameter of the piston assembly at the
portions shown in the left figure.
mm(in)
Standard Limit
0.04 - 0.125
(0.00158 - 0.00493)0.15 (0.00591)
Note:
If the clearance deviates from the range shown above,
replace the master cylinder and the piston assembly
together.

BRAKES 5-67
TROUBLESHOOTING
Condition and Cause Correction
Poor Brake Action
Master cylinder faulty Correct or replace
Power cylinder faulty Correct or replace
Level of brake fluid in reservoir too low Replenish and bleed
Air in hydraulic circuit Bleed
Front disc brake caliper faulty Clean or replace
Rear brake wheel cylinder faulty Clean or replace
Water or oil on brake pads or linings Clean or replace
Brake pads or linings hardened Replace
Brake pads or linings in poor contact with rotor or brake drum Correct
Brake pads or linings worn Replace
Brake disc or drum rusted Grind or replace
Check valve in vacuum hose faulty Correct or replace
Brake Squeak
Brake pads or linings worn Replace
Brake pads or linings hardened Replace
Brake pads or linings in poor contact with rotor or brake drum Correct
Brake disc(s) warped, worn or damaged Grind or replace
Disc brake anti-squeak shims fatigued Replace
Front hub bearings loose or preload is incorrect Adjust or replace
Brake disc or drum rusted Grind or replace
Brake Pull
Tire inflation pressures unequal Adjust
Front wheel alignment incorrect Adjust
Water or oil on brake pads or linings Clean or replace
Brake pads or linings hardened Replace
Brake pads or linings worn excessively Replace
Brake drum or rotor worn or scored Grind or replace
Front or rear wheel cylinder or disc brake caliper malfunctioning Clean or replace
Front hub bearing preload incorrect Adjust or replace
Brake pad or lining clearances unequal Adjust or replace
Brake Drag
Parking brake maladjusted Adjust
Brake pad or lining clearance insufficient Adjust
Brake pedal free play insufficient Adjust brake pedal height or power cylinder operating rod
Piston in master cylinder sticking Clean or replace
Pistons in disc brake caliper sticking Replace piston seals
Pistons in rear brake wheel cylinders sticking Clean or replace
Brake pads sticking in caliper Clean
Return springs weakened Replace
Parking brake binding Overhaul rear brakes
Front hub bearing preload incorrect Adjust or replace
Rear brake shoes not returning Correct or replace brake back plate, check automatic adjuster and
replace as necessary
Obstructions in hydraulic circuit Clean
Rotor warped excessively Grind or replace
Rear brake drum distorted Grind or replace
Piston cups swollen Replace brake fluid and piston cups
Check valve ; vacuum hose faulty Replace
Parking cable sticking Clean or replace
Rear disc brake over adjust Adjust or overhaul rear brakes
Excessive Brake Pedal Travel
Air in hydraulic circuit Bleed hydraulic circuit
Level of brake fluid in reservoir too low Replenish brake fluid reservoir to specified level and bleed hydraulic
circuit as necessary.
Master cylinder push rod clearance excessive Adjust
Leakage in hydraulic system Correct or replace defective parts
Rear disc brake autoadjuster malfunction Overhaul rear brakes

7C-20 CLUTCH
INSPECTION AND REPAIR
Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during
inspection.
PRESSURE PLATE ASSEMBLY
Visually inspect the pressure plate friction surface for
excessive wear and heat cracks.
If excessive wear or deep heat cracks are present, the
pressure plate must be replaced.
Pressure Plate Warpage
Use a straight edge and a feeler gauge to measure the
pressure plate friction surface flatness in four directions.
If any of the measured values exceed the specified limit, the
pressure plate must be replaced.
Pressure Plate Warpage mm(in)
Limit
0.3 (0.012)
Clutch Cover
Visually inspect the entire clutch cover for excessive wear,
cracking , and other damage.
The clutch cover must be replaced if any of these conditions
are present.
1. Abrasion, scratches, cracks and deflection of friction face to
the disc, loose rivet and wear of ring
Grind small scratches, or replace the assembly if extreme
scratches are found.