lock ISUZU TROOPER 1995 Owners Manual

7.
Fig. 4C-90
Lock washer and lock screw (Fig. 4C-91}
• Turn the side with larger diameter of the
tapered bore
to the vehicle outer side, and
attach the washer.
If the bolt holes in the lock plate are not aligned
with the corresponding holes in the nut, rotate
the
lock plate.
If
the bolt holes are still out of alignment, turn in
the
nut just enough to obtain alignment. Install
the lock screw so its head is lower than the
surface
of the washer .
•
Fig. 4C-91
6. Inner cam assembly
1) Before installation, make sure the transfer
lever is still in "2H" position.
1!1::1 2) Clean the flange surface of the hub, the thread
Lil holes, the surface of the lock washer and the
spline portion of the axle shaft (Fig. 4C-92).
FRONT DRIVING AXLE 4C-33
Fig. 4C-92
Install the inner cam by aligning the key way
with the groove in the knuckle (Fig. 4C-93).
NOTE:
The cam gear must be facing out.
Fig. 4C-93
• If it is difficult to install the inner cam, use the
tool (installer) and a plastic hammer or the
equivalent (Fig. 4C-94).
Install the special tool.
Use the plastic hammer to lightly tap around
the
special tool "A" surface as shown in the
illustration.
Installer:
J-38194
NOTE:
Do not strike the inner cam gear teeth with the
plastic hammer.

4C-34 FRONT DRIVING AXLE
\j
A
J-38194
IFn
Fig. 4C-94
Shim selection
1) Lower vehicle from hoist
2) Support lower link with floor jack, placing axle
in normal horizontal position (Fig. 4C-95).
~ 3)
Fig. 4C-95
Install special tool J-36836 to axle shaft with
J-36835-2 until it comes into contact with the
lock washer (Fig. 4C-96).
J-36835-2
Fig. 4C-96
~4) Using a feeler gauge, measure clearance "t"
between the shim and the snap ring groove of
the axle shaft (Fig. 4C-97).
Select and
install shims so that clearance "t" is
0 to 0.1 mm (0 to 0.0039 in) (Fig. 4C-97).
Thickness shims; 0.2, 0.3, 0.5, 1.0
mm
J-36836
Fig. 4C-97
5) Remove shim pack and special tool J-36836,
leaving the inner cam in position (Fig. 4C-99).
NOTE:
• If the inner cam is dislocated, repeat the
installation steps from the beginning.
• Be sure not to remove the special tool J-36835-2.
J-36836
Fig. 4C-98

FRONT DRIVING AXLE 4C-37
MAIN DATA AND SPECIFICATIONS
GENERAL SPECIFICATIONS
FRONT AXLE AND DIFFERENTIAL
4WD
Axle tube
Type
Gear type
Gear ratio
Differential type
Oil capacity
Axle shaft type
Hub locking
Type (to
1)
liter (US gal)
It consists of the
duct, a cast
iron housing and the axle tube.
Hypoid
4.555
Two pinion
1.5 (0.4)
Constant velocity joint (Birfield joint
type and double offset joint)
Automatic locking
hub

FRONT DRIVING AXLE 4C-41
SPECIAL TOOLS
ILLUSTRATION TOOL NO.
TOOL NAME ILLUSTRATION TOOL NO.
TOOL NAME
~
J-37221
Holder: Pinion flange @)
J-21777-42
Pilot
~
J-24250
Installer: Oil seal
'~
J-23597-9
Nut and bolt
@~lj
J-39378
Remover and Installer:
Front Axle mount bushing @
J-23597-7
Gauge plate
*
J-37264
Differential holding fixture
(Use
with J-3289-20 base)
+~? J-8001
~. Dial indicator
~
J-3289-20
Holding fixture base ~~
J-23597-8
Disc
"'"~
t>'"""_j~
J-22888
Puller: Side bearing
~
J-23597-1
Arbor
~
J-8107-2
Adapter: Side bearing plug
~
J-6133-01
Installer: Pinion bearing
~
J-22912-01
Separator
~
J-39209
Punch: End nut lock
@
J-24256
Installer:
Outer bearing
outer race
Eiij)
J-24244
Installer: Side bearing
~
J-8092
Driver handle Q
J-36827
Wrench: Hub nut
@)
J-24252
Installer: Inner bearing
outer race
~
J-36829
Installer: Inner bearing
outer race

4C-42 FRONT DRIVING AXLE
SPECIAL TOOLS
ILLUSTRATION TOOL NO.
TOOL NAME
~
J-36828
Installer:
Outer bearing
outer race
@
J-36830
Installer:
Oil seal
C®
J-38194
Inner cam installer
{{(I
J-36836
Shim gauge: Auto locking
hub
( [I J-36835
t! aJ I I It Installer: Snap ring
~
J-39602
Remover:
Outer bearing

HYDRAULIC BRAKES SA-1
BRAKES
w CAUTION:
• All
brake attaching fasteners are an important attaching part in that they could affect performance of vital
parts and systems, and/or could result in major repair expense. They must be replaced with one of the same
part
number or with an equivalent part if replacement becomes necessary. Do not use replacement parts of
lesser quality or substitute design. Torque values must be used as specified during reassembly to assure
proper retention
of these parts.
CONTENTS
Hydraulic Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section SA
Brake Booster System ........................................................ Section 5A1
Disc Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 5A2
Rear
Wheel Antilock Brake System (RWAL) .................................... Section 5A3
4-Wheel Antilock Brake System (ABS) ......................................... Section 5A4
Parking Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 5C
SECTION 5A
HYDRAULIC BRAKES
CONTENTS
Brake System Diagnosis ................ SA-2
Road
Testing the Brakes . . . . . . . . . . . . . . SA-2
Brake
Fluid Leaks . . . . . . . . . . . . . . . . . . . . SA-2
Warning Light Operation . . . . . . . . . . . . . SA-2
Antilock Brake System (RWAL or ABS) . SA- 2
Diagnosis of Brake System . . . . . . . . . . . . . . SA-3
On-Vehicle Service .................... SA- S
Filling Master Cylinder Reservoir . . . . . . . SA-S
Deterioration of Brake Fluid . . . . . . . . . . . SA-S
Leakage
of Brake Fluid . . . . . . . . . . . . . . . SA-S
Bleeding Brake Hydraulic System . . . . . . SA-S
Flushing Brake Hydraulic System . . . . . . SA-6
Brake Pipes
and Hoses . . . . . . . . . . . . . . . SA-6
Brake Hose
Inspection . . . . . . . . . . . . . . . SA-6
Brake Hose
Replacement . . . . . . . . . . . . . SA-7
Brake Pipe
Replacement . . . . . . . . . . . . . . SA-8
Combination Valve/P & B Valve . . . . . . . SA-9
Valve Replacement . . . . . . . . . . . . . . . . . . SA-1 0
Inspection of Brake Pad Lining . . . . . . . . SA-11
Inspection of Brake Rotors . . . . . . . . . . . . SA-11
Brake Pedal Assembly .................. SA-13 •
Checking Pedal Height ................ SA-13
Checking Pedal Travel ................ SA-13
Brake
Pedal Replacement ............. SA-14
Stoplight Switch Replacement ......... SA-1S
Master Cylinder Assembly ............... SA-16
General Description .................. SA-16
On-Vehicle Service ................... SA-17
Unit Repair .......................... SA-19
Main Data and Specifications ............ SA-21
General Specifications ................ SA-21
Torque Specifications ................ SA-21
Special Tools .......................... SA-22

SA-2 HYDRAULIC BRAKES
BRAKE SYSTEM DIAGNOSIS
ROAD TESTING THE BRAKES
Brake Test
Brakes should be tested on a dry, clean, reasonably
smooth and
level roadway. A true test of brake
performance cannot be made
if the roadway is
wet, greasy
or covered with loose dirt so that all
tires do not grip the road equally. Testing will also
be adversely affected if the roadway is crowned so
as to throw the weight of the vehicle toward
wheels on one side or if the roadway is so rough
that wheels tend to bounce. Test the brakes at dif­
ferent vehicle speeds with both light and heavy
pedal pressure; however, avoid locking the wheels
and sliding the tires. Locked wheels and sliding
tires do not indicate brake efficiency, since heavily
braked but turning wheels will stop the vehicle in
less distance than locked wheels. More tire-to-road
friction is present
with a heavily braked turning tire
then
with a sliding tire.
The standard brake system is designed and
balanced
to avoid locking the wheels except at very high
deceleration
levels.
It
is designed this way because the shortest stopping
distance and best
control is achieved without brake
lock-up.
Because of high deceleration capability, a firmer pedal
may be felt at higher deceleration levels.
External Conditions That Affect Brake
Performance
1.
2.
3.
Tires: Tires having unequal contact and grip on
the road
will cause unequal braking. Tires must
be equally inflated, identical in size, and the tread
pattern
of right and left tires must be approxi­
mately equal.
Vehicle loading:
A heavily loaded vehicle requires
more braking effort.
Wheel Alignment: Misalignment of the wheels,
particularly
in regard to excessive camber and
caster,
will cause the brakes to pull to one side.
BRAKE FLUID LEAKS
With engine running at idle and the transmission in
"Neutral", depress the brake pedal and hold a constant
foot pressure on the pedal. If pedal gradually falls
away with the constant pressure, the hydraulic system
may be leaking.
Check the master cylinder fluid level. While a slight
drop in reservoir level will result from normal lining
wear, an abnormally low level in reservoir indicates a
leak in the system. The hydraulic system may be
leaking internally as well as externally. Refer to
"Master Cylinder Inspection". Also, the system may
appear
to pass this test but still have slight leakage. If
fluid level
is normal, check the vacuum booster
push rod
length. If an incorrect length push rod is
found, adjust
or replace the push rod. Check the
brake
pedal travel and the parking brake adjust­
ment.
When checking the
fluid level, the master cylinder fluid
level
may be low from the "MAX" mark if the front and
rear
linings are worn. This is not abnormal.
WARNING LIGHT OPERATION
When the ignition switch is in the START position,
the
"BRAKE" warning light should glow and go off
when the ignition switch returns to the ON position.
The
following conditions will activate the "BRAKE"
light:
1. Parking brake applied. The light should be on
whenever the parking brake is applied and the
ignition switch is on.
2. Low fluid level. A low fluid level in the master
cylinder will turn the "BRAKE" light on (Except
Rear
Wheel Antilock Brake System (RWAL)
model).
3. During engine cranking the "BRAKE" light
should
remain on. This notifies the driver that
the warning circuit is operating properly.
4. In the event of a front or rear system malfunc­
tion (RWAL model only).
5. In the event of RWAL malfunction (RWAL
model only. Refer to Section 5A3).
ANTILOCK BRAKE SYSTEM (RWAL or
ABS}
Refer to Section 5A3 or 5A4 for inspection and di­
agnosis procedure of the hydraulic unit.
..

HYDRAULIC BRAKES 5A-5
ON-VEHICLE SERVICE
FILLING MASTER CYLINDER
RESERVOIR
'\fl CAUTION:
'VI • 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 fluids 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 contami­
nation.
• 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. The brake fluid reservoir is on the master
cylinder, which is located under the hood on the
left
side of the cowl. Thoroughly clean reservoir cap
before
removal to avoid getting dirt into reservoir.
Remove cap and diaphragm.
Add fluid as required to
bring level to the "MAX" mark on the reservoir tank.
Use
"DOT 3" Hydraulic Brake Fluid. If the fluid cap
diaphragm is stretched, return
it to the original position
before
installing.
DETERIORATION OF BRAKE FLUID
Using any other brake fluid than specified or brake fluid
with mineral oil or water mixed in will drop the boiling
point of brake fluid. It may, in turn, result in vapor lock
or deteriorated rubber parts of the hydraulic system.
Be sure to change brake fluid at specified intervals.
If rubber parts are deteriorated, remove all the system
parts and
clean them with alcohol. Prior to reassembly,
dry the cleaned parts with air to remove the alcohol.
Replace all
hoses and rubber parts of the system.
LEAKAGE OF BRAKE FLUID
With engine idling, set shift lever in the neutral position
and continue to depress brake
pedal at a constant
pressure.
Should the pedal stroke become deeper gradually,
leak from the hydraulic pressure system is possible.
Make sure
by visual check that there is no leak.
BLEEDING BRAKE HYDRAULIC SYSTEM
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 dis­
connecting 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 pipes are
disconnected at any fitting
located between master
cylinder and brakes, then the brake system served by
the disconnected pipe must
be bled.
1. For 4-wheel Antilock Brake System (ABS)
equipped
vehicle, be sure to remove the ABS
main fuse
40A located at the relay and fuse box
before
bleeding air. If you attempt to bleed air
without removing the main fuse, air cannot be let
out thoroughly, and this may cause damage to the
hydraulic unit.
After bleeding air, be sure to
replace the ABS main fuse back to its original
position.
2. 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.
3. Remove the master cylinder reservoir cap.
4. Fill the master cylinder reservoir with brake fluid.
Keep the reservoir at least half full during the air
bleeding operation.
5. Always use new brake fluid for replenishment.
6. In replenishing brake fluid, take care that air
bubbles do not enter the brake fluid.
•
When the master cylinder is replaced or
overhauled, first bleed the air from the master
cylinder, then from each
wheel cylinder and
caliper following the procedures described
below.
Bleeding the master cylinder (Fig. 5A-1}
7. Disconnect the rear wheel brake pipe master
cylinder (Fig. 5A-1 ). Check the fluid level
and replenish as necessary. If replenished, leave
the system for at least one minute.
8. Depress the brake pedal slowly once and hold it
depressed.
9. Completely seal the delivery port of the master
cylinder where the pipe was disconnected with
your finger, then release the brake pedal slowly.
10. Release your finger from the delivery port when
the brake
pedal returns completely.
11. Repeat steps 7 through 9 until the brake fluid
comes out of the delivery port during step 7.

COMBINATION VALVE/P & B
(PROPORTIONING AND BYPASS) VALVE
The combination valve/P & B valve contains two
sections, each serving a different function.
The proportioning section
of the combination valve/
P & B valve proportions outlet pressure to the rear
brakes after a predetermined rear
input pressure has
been reached. This is done to prevent rear
wheel lock­
up on the vehicles with light rear wheel loads.
The valve has a By-pass feature which assures full
system pressure to the rear brakes in the event of a
front brake system malfunction, also full front pressure
is retained in the event
of rear brake malfunction.
HYDRAULIC BRAKES 5A 9
The combination valve has a pressure differential
warning switch which is designed to constantly
compare front and rear brake pressure
from the
master
cylinder and turn on the brake system warning
light on the instrument panel in the event of a front or
rear system malfunction. The valve and switch are so
designed that the switch
will latch in the "warning"
position once a malfunction has occurred. The only
way the light can be turned off is to repair the
malfunction and
apply a pedal force required to
develop line pressure. The combination valve/P & B
valve is not repairable and must be replaced as a
complete assembly.
P&B valve
(Antilock brake system model only)
Master cylinder (Primary)
Combination valve (Rear wheel antilock model only)
Pressure differential warning switch
Master
cylinder (Secondary)
..(> ..(> Master cylinder (Secondary) Master
cylinder
(Primary)
..(> ..(>
Front brake
Rear brake
Combination Valve
Electrical Circuit Test (RWAL
model
Fig. 5A-4
only)
1.
2.
3.
Disconnect the wmng connector at the
combination
valve (Fig. 5A-5).
• Connect a jumper wire from the harness to
ground.
Turn the ignition key to
"ON".
•
The warning light should come on.
• If the light will not come on, check the bulb. If
the bulb is good, refer to Chassis Electrical
(Sec.
8) for further diagnosis.
Turn the ignition off.
• Disconnect jumper wire and connect the
harness to the switch
terminal.
Combination Valve (RWAL model only)
Warning
Switch Test
1. Raise the vehicle.
• Support
with suitable safety stands.
2. Attach a hose to a rear brake bleeder screw.
• Immerse the opposite end of the hose into a
container
partially filled with clean brake fluid.
3.
4.
5.
6.
7.
¢ Front RH brake
Front LH brake
Rear brake
• Make sure the master cylinder reservoir is full.
Turn the ignition key to "ON".
• Open
the bleeder screw while a helper applies
moderate pressure to the brake pedal.
•
The warning light should come on.
• Close the bleeder screw before the helper
releases
the brake pedal.
Reapply the brake pedal with moderate to heavy
pressure.
• The light should go out.
Attach a hose
to a front brake bleeder screw.
• Immerse the opposite end of the hose into a
container
partially filled with clean brake fluid.
• Make sure the master cylinder reservoir is full.
Turn the ignition key to "ON".
• Open
the bleeder screw while a helper applies
moderate pressure to the brake pedal.
•
The warning light should come on.
• Close the bleeder screw before the helper
releases
the brake pedal.
Reapply
the brake pedal with moderate to heavy
pressure.
• The light should go out.

HYDRAULIC BRAKES SA-13
BRAKE PEDAL ASSEMBL V
CHECKING PEDAL HEIGHT (Fig. SA-1 0)
The push rod serves as the brake pedal stopper when
the pedal is fully released. Brake pedal height
adjustment
should be performed as follows:
I~FI Adjust brake pedal
1. Measure the brake pedal height after making sure
the pedal is
fully returned by the pedal return
spring. Pedal height
(L2) must be measured after starting
the engine and revving
it several times (Fig. 5A-
10).
1~1 Pedal Free Play (L 1) mm (in) 6-10 (0.23- 0.39)
Pedal Height (L2)
NOTE:
mm (in) 208-218
(8.19-8.58)
Pedal free play (L 1) must be measured after turning off
the engine and stepping on the brake pedal firmly five
times
or more.
2. If the measured value is not within the above
range, adjust the brake
pedal as follows:
a) Disconnect the stoplight switch connector.
b) Loosen the stoplight switch lock nut.
c) Rotate the stoplight switch so that it moves
away
from the brake pedal.
d) Loosen the lock nut on the push rod.
e) Adjust the brake pedal to the specified height
by rotating the push rod in the appropriate
direction.
f) Tighten the lock nut to the specified torque.
~~~ Torque N·m (lb·ft) 20 (15) --------~----~---
Fig. 5A-10
g) Adjust the stoplight switch to the specified
clearance (between switch housing and brake
pedal)
by rotating the switch housing (Fig. 5A-
11 ).
1@1 Clearance mm (in) I 0.5-1.0 (0.02-0.04)
NOTE:
While adjusting the stoplight switch, make sure that
the threaded part of the stoplight switch does not push
the brake
pedal.
h) Tighten the stoplight switch lock nut.
i) Connect the stoplight switch connector.
Fig.
5A-11
CHECKING PEDAL TRAVEL (Fig. SA-1 0)
1. Pedal height (L3) must be measured after starting
the engine and revving
it several times to apply
vacuum
to the vacuum booster fully.
NOTE:
Pedal height (L3) must be 55 mm (2.2 in) or more when
about 50 kg (11 0.25 I b) of stepping force is applied.
2. If the measured value is lower than the above
range, air existing in the hydraulic system is
suspected and perform bleeding procedure.