ISUZU TROOPER 1998 Service Repair Manual

POWER ASSISTED BRAKE SYSTEM 5C – 53
DISASSEMBLY
1. Guide Bolt
2. Lock Bolt
3. Dust Boot; Guide Bolt and Lock Bolt
4. Dust Boot Ring
•Using a small screwdriver, remove the dust boot
ring.
REBUILDING THE CALIPER
4
6
5
7
3 8
3
2
1
9
Disassembly Steps
1. Guide bolt
2. Lock bolt
3. Dust boot; guide bolt and lock bolt
4. Dust boot ring
5. Piston
6. Dust boot; piston
7. Piston seal
8. Bleeder with cap
9. Caliper body
Reassembly Steps
9. Caliper body
8. Bleeder with cap
7. Piston seal
5. Piston
6. Dust boot; piston
4. Dust boot ring
3. Dust boot; guide bolt and lock bolt
2. Lock bolt
1. Guide bolt

5C – 54 POWER ASSISTED BRAKE SYSTEM
5. Piston
•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 to removal of dust
boot.
WARNING:
DO NOT PLACE YOUR FINGERS IN FRONT OF THE
PISTON IN AN ATTEMPT TO CATCH OR PROTECT IT
WHEN APPLYING COMPRESSED AIR. THIS COULD
RESULT IN PERSONAL INJURY.
CAUTION:
Use just enough air to ease the piston out of the
bore. If the piston is blown out, it may be damaged.
6. Dust Boot; Piston
7. Piston Seal
8. Bleeder with Cap
9. Caliper Body
REASSEMBLY
9. Caliper Body
8. Bleeder with Cap
Bleeder Torque N·m (kg·cm / lb·in)
8 (80 / 69)
7. Piston Seal
•Apply special rubber grease to the piston seal and
cylinder wall, then insert the piston seal into the
cylinder. The special rubber grease is included in
the repair kit.
INSPECTION AND REPAIR
Make necessary parts replacement, if wear, damage,
corrosion or any other abnormal conditions are found
through inspection.
Check the following parts;
•Rotor
•Cylinder body
•Cylinder bore
•Piston
•Guide bolt, Lock bolt
•Support bracket
NOTE:
The piston seal, boot ring and dust boot are to be
replaced each time the caliper is overhauled.
Discard these used rubber parts and replace with
new ones.
5. Piston

POWER ASSISTED BRAKE SYSTEM 5C – 55
6. Dust Boot; 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
piston seal can result.
4. Dust Boot Ring
•Apply special grease (Approx. 1 g) to the piston
and attach the dust boot to the piston and caliper.
Insert the dust boot ring into the dust boot.
3. Dust Boot; Guide Bolt and Lock Bolt
2, 1. Lock Bolt and Guide Bolt
Lock and Guide Bolt Torque N·m (kg·m / lb·ft)
74 (7.5 / 54)
•Install the dust boot on the support bracket after
applying special grease (Approx. 1 g) onto the
dust boot inner surface. Also apply special grease
onto the lock bolt and guide bolt setting hole of
the support bracket.

5C – 56 POWER ASSISTED BRAKE SYSTEM
REAR DISC BRAKE
BRAKE PADS REPLACEMENT
1
5
5
3
2
4
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 rear brake while
driving, check the pad wear indicator plate. If the
indicator plate contacts the rotor, the disc pad
assembly should be replaced.
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.
2. Lock Bolt

POWER ASSISTED BRAKE SYSTEM 5C – 57
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
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 shim
Wear indicator
Apply
special
grease
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.

5C – 58 POWER ASSISTED BRAKE SYSTEM
2. Lock Bolt
Lock Bolt Torque N·m (kg·m / lb·ft)
44 (4.5 / 32)
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.

POWER ASSISTED BRAKE SYSTEM 5C – 59
CALIPER REPLACEMENT
7
1
4
6
8
8
5
2
3
Removal Steps
1. Wheel and tire assembly
2. Brake flexible hose
3. Lock bolt
4. Guide bolt
5. Caliper assembly
6. Support bracket
7. Pad assembly with shim
8. Clip
Installation Steps
To install, follow the removal steps in the
reverse order.
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.

5C – 60 POWER ASSISTED BRAKE SYSTEM
3. Lock Bolt
4. Guide Bolt
4
3
5. Caliper Assembly
6 Support Bracket
•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
Clip
7. 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 shim
Wear indicator
6. Support Bracket
Support Bracket Torque N·m (kg·m / lb·ft)
104 (10.6 / 77)
5. Caliper Assembly

POWER ASSISTED BRAKE SYSTEM 5C – 61
4. Guide Bolt
3. Lock Bolt
Lock Bolt Torque N·m (kg·m / lb·ft)
44 (4.5 / 32)
3
4
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)
Hooked edge
Gasket
1. Wheel and Tire Assembly
1) Refer to Wheels and Tires in Suspension section.
2) Bleed brakes.

5C – 62 POWER ASSISTED BRAKE SYSTEM
REBUILDING THE CALIPER
3465
7
9
1
23
8
Disassembly Steps
1. Guide bolt
2. Lock bolt
3. Dust boot
4. Dust boot ring
5. Piston
6. Dust boot; piston
7. Piston seal
8. Bleeder with cap
9. Caliper body
Reassembly Steps
9. Caliper body
8. Bleeder with cap
7. Piston seal
5. Piston
6. Dust boot; pisotn
4. Dust boot ring
3. Dust boot
2. Lock bolt
1. Guide bolt
DISASSEMBLY
1. Guide Bolt
2. Lock Bolt
3. Dust Boot
4. Dust Boot Ring
•Using a small screwdriver, remove the dust boot
ring.