brake ISUZU TFS SERIES 1997 Repair Manual

5-34 BRAKES
Important Operations
5. Dust Seal Ring
Using a small screwdriver, remove the dust boot.
7. Piston (with Ring Seal)
Insert a block of wood into the caliper and force out the piston
by blowing compressed air into the caliper at the flexible hose
attachment.
This procedure must be done prior tor removal of dust seal.
CAUTION:
Do not place your fingers in front of the piston in an
attempt to catch or protect it when applying compressed
air.

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.

5-36 BRAKES
Thickness of Disc Pad
Thickness (t) mm(in)
Standard Limit
10.5 (0.413)
9.5 (0.374)
(For Australia only)1.0 (0.039)
Replace the front disc pad whenever the pad wear indicator
makes a squeaking noise or when the pad is worn to within 1
mm of the shoe table.
All four brake pads should be replaced together.
Seal and Boot
The dust seal, dust boot and ring seal are to be replaced each
time the caliper is overhauled.
Discard thee used rubber parts.

BRAKES 5-37
REASSEMBLY
CALIPER ASSEMBLY
Disassembly Steps
1. Body ; caliper
2. Ring seal
3. Piston
4. Dust seal ; piston
5. Dust seal ring
6. Dust boot ; sleeve
7. Dust boot ; guide pin
8. Sleeve
9. Bleeder with cap
Important Operations
1. Body ; Caliper
2. Ring Seal
Apply special grease to the ring seal and cylinder wall, then
insert the ring seal into the cylinder.
The special grease is included in the repair kit.

5-38 BRAKES
3. Piston
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.
4. Dust Seal ; Piston
5. Dust Seal Ring
Apply special grease (Approx. 1g) to the piston and attach the
dust seal to the piston and caliper.
Insert the dust seal ring into the dust seal.
6. Dust Boot ; Sleeve
7. Dust Boot ; Guide Pin
Install the sleeve dust boot on the caliper after applying special
grease (Approx. 1g) into the sleeve and guide pin boot, then
insert the sleeve into the dust boot.
9. Bleeder with Cap
Torque N
m(kgfm/Ibft)
5.9-8.8 (0.6 - 0.9 / 4.3 - 6.5)

BRAKES 5-39
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.
MAJOR COMPONENTS
Disassembly Steps
1. Brake line
2. Holding spring and cups
3. Return spring ; lower
4. Return Spring ; upper
(shoe to adjust lever)
5. Return spring ; upper
(shoe to shoe)
6. Shoe assembly (primary)7. Shoe assembly with lever
8. Retainer with pin
9. Washer ; wave
10. Lever ; auto adjust
11. Shoe assembly (secondary)
12. Adjuster assembly
13. Wheel cylinder assembly
MINOR COMPONENTS
Disassembly Steps
Wheel Cylinder Assembly (13)
14. Boot ; wheel cylinder
15. Piston assembly
16. Cup ; piston17. Return spring ; piston
18. Bleeder ; wheel cylinder

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 5-41
Free length
mm(in.)Set length
mm(in.)Set load
kg(lbs.)
Return spring :
upper
(adjust lever)124.9
(4.917)134.9
(5.311)70.7
(15.4
1.6)
Shoe return
spring : upper112.4
(4.425)121.5
(4.783)20.2
(4.4
0.4)
Shoe return
spring : lower167.2
(6.583)190.2
(7.488)28.02.8
(61.7
6.4)
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.
Clearance Between the Wheel Cylinder
and the Piston
mm(in)
Standard Limit
0.02 - 0.1(0.001 - 0.004) 0.15(0.006)
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 0.05(0.002) 0.15(0.006)
Inside diameter 295(11.614) 296.5(11.673)
Run out 0.05(0.02) 0.15(0.006)TFS
TFR

5-42 BRAKES
REASSEMBLY
MINOR COMPONENTS
Reassembly Steps
Wheel cylinder Assembly (7)
1. Bode ; wheel cylinder
2. Return spring ; piston
3. Cup ; piston4. Piston assembly
5. Boot ; wheel cylinder
6. Bleeder ; wheel cylinder
MAJOR COMPONENTS
Reassembly Steps
7. Wheel cylinder assembly
8. Adjuster assembly
9. Shoe assembly (secondary)
10. Lever ; auto adjuster
11. Washer ; wave
12. Retainer with pin
13. Shoe assembly (primary)14. Return spring ; upper
(shoe to shoe)
15. Return spring ; upper
(shoe to adjust lever)
16. Return spring ; lower
17. Holding spring and cups
18. Brake line

BRAKES 5-43
Important Operations
1. Bode ; Wheel Cylinder
Lubricate the cylinder bore with clean rubber grease.
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.
Apply DELCO silicone lube No.5459912 (or equivalent) to the
piston and the inner face of the boots.
6. Bleeder ; Wheel Cylinder
Torque N
m(kgfm/Ibft)
6.9 - 11.8 (0.7 - 1.2 / 5.1 - 8.7)
7. Wheel Cylinder Assembly
Torque N
m(kgfm/Ibft)
11 - 15 (1.1 - 1.5 / 8 - 11)