ISUZU TROOPER 1998 Service Repair Manual

POWER ASSISTED BRAKE SYSTEM 5C – 43
2) Set push rod gauge on vacuum booster, and
apply negative pressure by means of vacuum
pump so that the pressure in the vacuum booster
becomes 500 mm Hg.
NOTE:
Be sure to apply. NEGATIVE
pressure after installing
a push rod gauge on vacuum booster.
3) Measure dimension L
Dimension L(Standard) mm
0 ± 0.1
5-8840-0279-05-8840-2300-0
L
5-8840-2300-0
4) If dimension Lis out of the standard range,
adjust push rod using the special tool.
5) Mount plate and seal assembly in vacuum
booster front shell. Then install retainer.
4. Vacuum Booster Fixing Nut
Vacuum Booster Fixing Nut Torque N·m (kg·m / lb·ft)
21 (2.1 / 16)
3. Yoke Clevis
2. Vacuum Hose
•In case of the gasoline engine model, make sure
that the arrow on the hose points in the direction of
the engine.
1. Master Cylinder
•Refer to Master Cylinder Assembly in this Section.
5-8840-2305-0 T-wrench

5C – 44 POWER ASSISTED BRAKE SYSTEM
EXTERIOR COMPONENTS
P&B valve
equipped
vehicle
LSPV
equipped
vehicle
1 10 11
2 9 3
4
5
6
7
8
Removal Steps
1. Master cylinder
2. Vacuum booster
3. Yoke clevis
4. Lock nut
5. Retaining clip
6. Valve body guard
7. Silencer
8. Filter
9. 2 gaskets and spacer
10. Retainer
11. Plate and seal assembly
Installation Steps
To install, follow the removal steps in the
reverse order.
This illustration is based on the LHD model.
331RW011

POWER ASSISTED BRAKE SYSTEM 5C – 45
REMOVAL
1. Master Cylinder
•Refer to Master Cylinder Assembly in this Section.
2. Vacuum Booster
•Refer to Vacuum Booster Assembly in this
section.
3. Yoke Clevis
4. Lock Nut
5. Retaining Clip
6. Valve Body Guard
7. Silencer
8. Filter
9. 2 gaskets and Spacer
10. Retainer
•Use a small screwdriver to pry out the retainer.
Gently pull out the plate and seal assembly from
the shell.
11. Plate and Seal Assembly
INSPECTION AND REPAIR
Visual Check:
Make necessary parts replacement if cuts, nicks,
excessive wear, or other abnormal conditions are
found through inspection. Check the following parts.
1) Yoke clevis
2) Valve body guard
3) Silencer
4) Filter
5) Plate and seal assembly
INSTALLATION
11. Plate and Seal Assembly
10. Retainer
9. 2 gaskets and Spacer
8. Filter
7. Silencer
6. Valve Body Guard
5. Retaining Clip
4. Lock Nut
Lock Nut Torque N·m (kg·m / lb·ft)
20 (2.0 / 15)

5C – 46 POWER ASSISTED BRAKE SYSTEM
3. Yoke Clevis
2. Vacuum Booster
•Refer to Vacuum Booster Assembly in this
section.
1. Master Cylinder
1) Refer to Master Cylinder Assembly in this Section.
2) After installation, perform brake pedal check and
adjustment. Refer to Checking Brake Pedal Height
/ Travel in this section.

POWER ASSISTED BRAKE SYSTEM 5C – 47
FRONT DISC BRAKE
BRAKE PADS REPLACEMENT
Outer side1
2
3
45
5
Removal Steps
1. Wheel and tire assembly
2. Lock bolt
3. Caliper assembly
4. Pad assembly with shim
5. Clip
Installation Steps
To install, follow the removal steps in the
reverse order.
REMOVAL
NOTE:
If a squealing noise occurs from the front brake while
driving, check the pad wear indicator plate. If the
indicator plate contacts the rotor, the disc pad
assembly should be replaced.
Preparation:
1) Draw out two-thirds of the brake fluid from the
reservoir.
2) Raise the vehicle and support it with suitable
safety stands.
1. Wheel and Tire Assembly
•Refer to Wheels and Tires in Suspension section.

5C – 48 POWER ASSISTED BRAKE SYSTEM
2. Lock Bolt
3. Caliper Assembly
•Support the caliper assembly so that the brake
hose is not stretched or damaged.
4. Pad Assembly with Shim
5. Clip
INSTALLATION
5. Clip
4. Pad Assembly with Shim
•Apply special grease (approx 0.2 g) to both
contacting surfaces of inner shims. Wipe off
extruded grease after installing.
Inner sideInner shim
Wear indicator
Apply
special
grease

POWER ASSISTED BRAKE SYSTEM 5C – 49
3. Caliper Assembly
1) Use adjustable pliers to bottom the piston into the
caliper bore. Be careful not to damage the piston
dust boot.
2) Do not damage the flexible hose by twisting or
pulling it.
2. Lock Bolt
Lock Bolt Torque N·m (kg·m / lb·ft)
74 (7.5 / 54)
1. Wheel and Tire Assembly
1) Refer to Wheels and Tires in Suspension section.
2) Pump the brake pedal several times to make sure
that the pedal is firm. Check the brake fluid level
in the reservoir after pumping the brakes.

5C – 50 POWER ASSISTED BRAKE SYSTEM
REMOVAL
Raise the vehicle and support with suitable safety
stands
1. Wheel and Tire Assembly
•Refer to Wheels and Tires in Suspension section.
2. Brake Flexible Hose
1) Remove the bolt and gaskets, then disconnect the
flexible hose from the caliper.
2) After disconnecting the flexible hose, cap or tape
the openings to prevent entry of foreign material.
3) Since the brake fluid flows out from the
connecting coupler, place a drain pan under the
vehicle.
CALIPER REPLACEMENT
Outer side
4
3
2
758
8
6
1
Removal Steps
1. Wheel and tire assembly
2. Brake flexible hose
3. Guide bolt
4. Lock bolt
5. Caliper assembly
6. Support bracket with pad assembly
7. Pad assembly with shim
8. Clip
Installation Steps
To install, follow the removal steps in the
reverse order.

POWER ASSISTED BRAKE SYSTEM 5C – 51
3. Guide Bolt
4. Lock Bolt
5. Caliper Assembly
6. Support Bracket with Pad Assembly
•Take care not to damage the flexible brake hose
when removing the support bracket.
7. Pad Assembly with Shim
•Mark the lining locations if they are to be
reinstalled.
8. Clip
INSTALLATION
8. Clip
7. Pad Assembly with Shim
•Apply special greae (approx 0.2 g) to the both
contacting surfaces of inner shims. Wipe off
extruded grease after installing.
6. Support Bracket
Support Bracket Torque N·m (kg·m / lb·ft)
155 (15.8 / 115)
4
3
Inner sideInner shim
Wear indicator

5C – 52 POWER ASSISTED BRAKE SYSTEM
5. Caliper Assembly
4, 3. Lock Bolt and Guide Bolt
Lock Bolt and Guide Bolt Torque N·m (kg·m / lb·ft)
74 (7.5 / 54)
2. Brake Flexible Hose
1) Always use new gaskets.
2) Be sure to put the hooked edge of the flexible
hose end into the anti-rotation cavity.
Brake Flexible Hose Torque N·m (kg·m / lb·ft)
35 (3.5 / 26)
1. Wheel and Tire Assembly
1) Refer to Wheels and Tires in Suspension section.
2) Bleed brakes. Refer to Bleeding Brake Hydraulic
System in this section.
Hooked edge
Gasket