ISUZU TFS SERIES 1997 Workshop Manual

BRAKES 5-53
VACUUM SERVO
REMOVAL AND INSTALLATION
Removal Steps
1. Clamp ; vacuum hose
2. Vacuum hose
3. Brake line
4. Return spring ; brake pedal
5. Snap pin
6. Pin ; push rod to brake pedal
7. Vacuum servo to dash panel and pedal
mounting bracket
8. Maser cylinder assembly
9. Vacuum servo assembly
Installation Steps
9. Vacuum servo assembly
8. Maser cylinder assembly
7. Vacuum servo to dash panel and pedal
mounting bracket
6. Pin ; push rod to brake pedal
5. Snap pin
4. Return spring ; brake pedal
3. Brake line
2. Vacuum hose
1. Clamp ; vacuum hose

5-54 BRAKES
Important Operation - Removal
3. Brake Line
When handling, be careful not to spill brake fluid over the
painted surfaces, as damage to the paint finish will result.
Important Operation - Installation
8. Master Cylinder Assembly
Check the distance from the flange face of the vacuum servo
to the end of the push rod before installation of the master
cylinder.
Projection (A) mm(in)
18.0 - 18.2 (0.709 - 0.717)
If the measured distance deviates from the specified range,
make an adjustment with the lock nut
1 at the end of the push
rod.
Torque N
m(kgfm/lbft)
15 - 25 (1.5 - 2.5 / 11 - 18)
7. Vacuum Servo to Dash Panel and Pedal Mounting
Bracket
Torque N
m(kgfm/lbft)
22 - 31 (2.2 - 3.2 / 16 - 23)
Apply sealer to the dashboard fitting face.
3. Brake Line
Torque N
m(kgfm/lbft)
9 - 15 (0.9 - 1.5 / 6.5 - 11)

BRAKES 5-55
2. Vacuum Hose
1) W hen removing or replacing the vacuum hose make sure
that the arrow on the label of the hose is facing the engine.
2) Also confirm that the check valve is facing the engine.

5-56 BRAKES
PARKING BRAKE (STEM TYPE)
REMOVAL AND INSTALLATION
PARKING BRAKE STEM ASSEMBLY (LEFT HAND DRIVE MODEL)
Removal Steps
1. Cable front, relay lever side
2. Bolt ; bracket to dash
3. Bolt ; bracket to cross beam
4. Parking brake stem assembly
Installation Steps
To install, follow the removal procedure in
reverse order.

BRAKES 5-57
PARKING BRAKE STEM ASSEMBLY (RIGHT HAND DRIVE MODEL)
Removal Steps
1. Bolt and nut
2. Collar
3. Roller
4. Cable front, relay lever side
5. Nuts ; bracket to dash
6. Bolt ; bracket to cross beam
7. Parking brake stem assembly
8. Nuts
9. Bracket ; roller
Installation Steps
To install, follow the removal procedure in
reverse order.
Before installation, apply chassis grease to the
roller (3)'s contact surface to the collar (2) and
cable (4).

5-58 BRAKES
FRONT AND REAR CABLE ASSEMBLY
Removal Steps
1. Nut
2. Equalizer bracket
3. Snap pin, with plan washer
4. Pin with curved washer
5. Cable ; front lower
6. Pin with curved washer
7. Parking brake stem assembly
8. Nuts
9. Clip
10. Clip ; fixing bracket
11. Cable assembly ; rear
12. 2nd relay lever assembly with return
spring
13. 1st relay lever assembly
Installation Steps
13. 1st relay lever assembly
12. 2nd relay lever assembly with return
spring
11. Cable assembly ; rear
10. Clip ; fixing bracket
9. Clip
8. Nuts
7. Parking brake stem assembly
6. Pin with curved washer
5. Cable ; front lower
4. Pin with curved washer
3. Snap pin, with plan washer
2. Equalizer bracket
1. Nut

BRAKES 5-59
Important Operations - Removal
11.Cable Assembly ; Rear
When abrasion or wear is evident on edge protector, in must
be replaced with new one.
Important Operations - Installation
13.1st Relay Lever Assembly
Apply grease (BESCO L-2 or equivalent) to the inner and outer
surface of the bushes and cable connecting portions.
12.2nd Relay Lever Assembly with Return Spring
Apply grease (BESCO L-2 or equivalent) to the arrowed portion
in the left figure.
8. Intermediate Cable
After applying grease (BESCO L-2 or equivalent) to the cable
guide, set it to the bracket by striking lightly with a mallet.

5-60 BRAKES
Apply grease (BESCO L-2 or equivalent) to the arrowed portion
in the left figure.
7. Pin with Curved Washer
Apply grease (BESCO L-2 or equivalent) to the circumference
of the pin and joint.
6. Snap pin, with Plain Washer
3. Snap pin, with Plain Washer
Discard the used snap pins and use new parts.

BRAKES 5-61
DISASSEMBLY AND REASSEMBLY
PARKING BRAKE STEM ASSEMBLY
This illustration is based on the LHD model
Disassembly Steps
1. Switch ; parking brake and bolt
2. Cable ; front
3. Switch actuating pin
4. Stem
5. Spring
6. Pole
Reassembly Steps
6. Pole
5. Spring
4. Stem
3. Switch actuating pin
2. Cable ; front
1. Switch ; parking brake and bolt

5-62 BRAKES
Important Operations - Disassembly
2. Cable ; Front
Manually release the lever ratchet and depress the stem until
the cable attachment at the lower end of the stem is visible.
Remove the cable from the stem lower end.
3. Switch Actuating Pin
Align the parking brake switch actuating pin with the hole in the
housing.
Using a flat head punch, drive out the pin.
Important Operations - Reassembly
6. Pole
4. Stem
Before reassembly, apply chassis grease to the arrowed
portion in the left figures.
2. Cable ; Front
Before reassembly, apply chassis grease to the entire inside
surface of the cable boot (arrowed in the left figure)fully.