brake pads ISUZU TROOPER 1998 Service Repair Manual

0AÐ8 GENERAL INFORMATION
LIFTING INSTRUCTIONS
CAUTION:
·If a lifting device other than the original jack
is used, it is most important that the device
be applied only to the correct lifting points.
Raising the vehicle from any other point
may result in serious damage.
·When jacking or lifting a vehicle at the
frame side rail or other prescribed lift
points, be certain that lift pads do not
contact the catalytic converter, brake
pipes or cables, or fuel lines. Such contact
may result in damage or unsatisfactory
vehicle performance.
LIFTING POINTS AND SUPPORTABLE POINT LOCATIONS
Long wheel Base Model
Short Wheel Base Model
Lifting point
Supportable point

0BÐ2 MAINTENANCE AND LUBRICATION
MAINTENANCE SCHEDULE
GASOLINE ENGINE MODELI: Inspect and correct or replace as necessary A: Adjust
R: Replace or change T: Tighten to specified torque L: Lubricate
SERVICE INTERVAL: x 1,000 km
(Use odometer reading x 1,000 miles
or months whichever comes first) or months5
3
610
6
1215
9
1820
12
2425
15
3030
18
3635
21
4240
24
4845
27
5450
30
6055
33
6660
36
7265
39
7870
42
8475
45
9080
48
9685
51
10290
54
10895
57
114100
60
120
GASOLINE ENGINE
* Engine oil
* Engine oil filter
Oil leakage and contamination
* Timing belt
Spark plugs (For leaded fuel use)
Spark plugs (For unleaded fuel use)
Exhaust system
Radiator coolant concentration
Cooling system for water leakage
All hoses and pipes in engine compartment
for clog or damage
Fuel filter
Fuel leakage
Fuel tank
* Air cleaner element
Pre air cleaner
Engine drive belt
Valve clearance
O
2 Sensor (For leaded fuel use)
O
2 Sensor (For unleaded fuel use)-
-
-
-
-
-
-
-
-
-
-
-
-
-
--
-
-
-
-
-
-
-
-
-
-
-
-
-
-R
R
R
-
I
I
I
I
-
I
I
I
I
-
--
-
-
-
-
-
-
-
-
-
-
-
-
-
--
-
-
-
-
-
-
-
-
-
-
-
-
-
-R
R
I
-
I
I
I
I
R
I
I
I
I
I
--
-
-
-
-
-
-
-
-
-
-
-
-
-
--
-
-
R
-
-
-
-
-
-
-
-
-
-
-R
R
I
-
I
I
I
I
-
I
I
R
I
-
--
-
-
-
-
-
-
-
-
-
-
-
-
-
R-
-
-
-
-
-
-
-
-
-
-
-
-
-
-R
R
I
-
I
I
I
I
R
I
I
I
I
I
--
-
-
-
-
-
-
-
-
-
-
-
-
-
--
-
-
-
-
-
-
-
-
-
-
-
-
-
-R
R
I
-
I
I
I
I
-
I
I
I
I
-
--
-
-
R
-
-
-
-
-
-
-
-
-
-
--
-
-
-
-
-
-
-
-
-
-
-
-
-
-R
R
I
-
I
I
I
I
R
I
I
R
I
I
--
-
-
-
-
-
-
-
-
-
-
-
-
-
--
-
-
-
-
-
-
-
-
-
-
-
-
-
R
(Replace every 165,000 km or 100,000 miles)
(Replace every 165,000 km or 100,000 miles)
(Check and adjust if necessary every 100,000 km or 60,000 miles)
(Replace every 150,000 km or 90,000 miles)
CLUTCH
Clutch fluid
Clutch pedal travel and free play
TRANSMISSION OR TRANSMISSION WITH
TRANSFER CASE
* Manual transmission with transfer case oil
* Automatic transmission fluid leakage
*
(1)Automatic transmission fluid
* Transfer case oil
PROPELLER SHAFT
Loose connections
*
Universal joints and splines for wear
Universal joints and sliding sleeve (front and rear)
FRONT AND REAR AXLE
* Differential gear oil (Front and rear)
Shift on the fly system gear oil
Front axle shaft rubber boot for damage
Axle case for distortion or damage
Axle shafts for distortion or damage-
-
-
-
-
-
-
-
-
-
-
-
-
--
-
-
-
-
-
-
-
-
-
-
-
-
-I
I
R
I
-
R
I
I
L
R
I
I
I
I-
-
-
-
-
-
-
-
-
-
-
-
-
--
-
-
-
-
-
-
-
-
-
-
-
-
-I
I
I
I
-
I
I
I
L
I
I
I
I
I-
-
-
-
-
-
-
-
-
-
-
-
-
--
-
-
-
-
-
-
-
-
-
-
-
-
-I
I
R
I
-
R
I
I
L
R
I
I
I
I-
-
-
-
-
-
-
-
-
-
-
-
-
--
-
-
-
-
-
-
-
-
-
-
-
-
-I
I
I
I
-
I
I
I
L
I
I
I
I
I-
-
-
-
-
-
-
-
-
-
-
-
-
--
-
-
-
-
-
-
-
-
-
-
-
-
-I
I
R
I
-
R
I
I
L
R
I
I
I
I-
-
-
-
-
-
-
-
-
-
-
-
-
--
-
-
-
-
-
-
-
-
-
-
-
-
-I
I
I
I
-
I
I
I
L
I
I
I
I
I-
-
-
-
-
-
-
-
-
-
-
-
-
--
-
I
-
I
I
-
-
-
I
-
-
-
-
ATATAT
STEERING
* Power steering fluid
Oil leakage
* Steering system for looseness or damage
Power steering hose
Steering wheel play
Steering function
Right and left turning radius
Wheel alignment
Joint ball for oil leakage or damage
Joint ball rubber boot for damage
SERVICE BRAKES
Brake fluid
Brake system for fluid leakage
Brake function
* Disc brake pads and discs wear
Brake pedal travel and free play
Pipes and hoses for loose connections or damage
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
--
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-I
I
I
I
I
I
-
-
I
I
I
I
I
I
I
I-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
--
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
--
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-R
I
I
I
I
I
-
-
I
I
R
I
I
I
I
I-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
--
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
--
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-I
I
I
R
I
I
-
-
I
I
I
I
I
I
I
I-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
--
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-R
I
I
I
I
I
I
I
I
I
R
I
I
I
I
I-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
--
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
(1): Adjust or change automatic transmission fluid.
*Marks: Under severe driving conditions, additional maintenance is required.
Refer to “Maintenance schedule under severe driving conditions”.

0BÐ4 MAINTENANCE AND LUBRICATION
DIESEL ENGINE MODELI: Inspect and correct or replace as necessary A: Adjust
R: Replace or change T: Tighten to specified torque L: Lubricate
SERVICE INTERVAL: x 1,000 km
(Use odometer reading x 1,000 miles
or months whichever comes first) or months5
3
610
6
1215
9
1820
12
2425
15
3030
18
3635
21
4240
24
4845
27
5450
30
6055
33
6660
36
7265
39
7870
42
8475
45
9080
48
9685
51
10290
54
10895
57
114100
60
120
DIESEL ENGINE
* Engine oil
* Engine oil filter
Oil leakage and contamination
Idling speed and acceleration
Fan belt tension and damage
Timing belt
Exhaust system
All hoses and pipes in engine compartment
for clog or damage
Valve clearance
* Air cleaner element
Fuel filter
Radiator coolant concentration
Cooling system for water leakage-
-
-
-
-
-
-
-
-
-
-
-R
R
I
I
I
I
I
-
-
-
I
I-
-
-
-
-
-
-
-
-
-
-
-R
R
I
I
I
I
I
A
-
-
I
I-
-
-
-
-
-
-
-
-
-
-
-R
R
I
I
I
I
I
-
-
-
I
I-
-
-
-
-
-
-
-
-
-
-
-R
R
I
I
I
I
I
-
-
-
I
I-
-
-
-
-
-
-
-
-
-
-
-R
R
I
I
I
I
I
A
-
-
I
I-
-
-
-
-
-
-
-
-
-
-
-R
R
I
I
I
I
I
-
-
-
I
I-
-
-
-
-
-
-
-
-
-
-
-R
R
I
I
I
I
I
-
-
-
I
I-
-
-
-
-
-
-
-
-
-
-
-R
R
I
I
I
I
I
A
R
R
I
I-
-
-
-
-
-
-
-
-
-
-
-R
R
I
I
I
I
I
-
-
-
I
I-
-
-
-
-
-
-
-
-
-
-
-R
R
I
I
I
I
I
-
-
-
I
I
NOTE: In the 4JXI-TC diesel engine, there is provided sub (2nd) oil filter for fuel injection at the upper part of crank case on the left
side of the engine. This oil filter maintenance-free and does not need a periodic replacement. See reverse side the (back)
cover for installation location of the sub (2nd) oil filter.(Replace every 200,000 km or 125,000 miles)
*Marks: Under severe driving conditions, additional maintenance is required.
Refer to “Maintenance schedule under severe driving conditions”. CLUTCH
Clutch fluid
Clutch pedal travel and free play
TRANSMISSION OR TRANSMISSION WITH
TRANSFER CASE
* Manual transmission with transfer case oil
* Automatic transmission fluid
* Transfer case oil
PROPELLER SHAFT
Loose connections
* Universal joints and splines for wear
Universal joints and sliding sleeve (front and rear)FRONT AND REAR AXLE
* Differential gear oil (Front and rear)
Shift on the fly system gear oil
Front axle shaft rubber boot for damage
Axle case for distortion or damage
Axle shafts for distortion or damage-
-
-
-
-
-
-
-
-
-
-
-
-I
I
R
-
R
I
I
L
R
-
-
-
--
-
-
-
-
-
-
-
-
-
-
-
-I
I
I
I
I
I
I
L
I
I
I
I
I-
-
-
-
-
-
-
-
-
-
-
-
-I
I
-
-
-
I
I
L
-
-
-
-
--
-
-
-
-
-
-
-
-
-
-
-
-I
I
R
I
R
I
I
L
R
I
I
I
I-
-
-
-
-
-
-
-
-
-
-
-
-I
I
-
-
-
I
I
L
-
-
-
-
--
-
-
-
-
-
-
-
-
-
-
-
-I
I
I
I
I
I
I
L
I
I
I
I
I-
-
-
-
-
-
-
-
-
-
-
-
-I
I
-
-
-
I
I
L
-
-
-
-
--
-
-
-
-
-
-
-
-
-
-
-
-I
I
R
I
R
I
I
L
R
I
I
I
I-
-
-
-
-
-
-
-
-
-
-
-
-I
I
-
-
-
I
I
L
-
-
-
-
--
-
-
-
-
-
-
-
-
-
-
-
-I
I
I
I
I
I
I
L
I
I
I
I
I
ATAT
STEERING
* Power steering fluid
Oil leakage
* Steering system for looseness or damage
Power steering hose
Steering wheel play
Steering function
Right and left turning radius
Wheel alignment
Joint ball for oil leakage or damage
Joint ball rubber boot for damage
SERVICE BRAKES
Brake fluid
Brake system for fluid leakage
Brake function
* Disc brake pads and discs wear
Brake pedal travel and free play
Pipes and hoses for loose connections or damage
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-I
I
I
I
I
I
-
-
I
I
-
I
I
I
I
I-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-I
I
I
I
I
I
-
-
I
I
-
I
I
I
I
I-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-R
I
I
I
I
I
I
I
I
I
R
I
I
I
I
I-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-I
I
I
I
I
I
-
-
I
I
-
I
I
I
I
I-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-I
I
I
R
I
I
-
-
I
I
-
I
I
I
I
I-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-R
I
I
I
I
I
I
I
I
I
R
I
I
I
I
I-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-I
I
I
I
I
I
-
-
I
I
-
I
I
I
I
I-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I

0BÐ6 MAINTENANCE AND LUBRICATION
Item IntervalCondition
ABCD A+D
Engine oil G : Change every 5,000 km (3,000 miles)
D : Change every 5,000 km (3,000 miles) ll
Engine oil filter G : Replace every 10,000 km (6,000 miles)
D : Replace every 5,000 km (3,000 miles) ll
Air cleaner element G : Replace every 20,000 km (12,000 miles)
D : Replace every 40,000 km (25,000 miles)l
Power steering fluid Replace every 50,000 km (30,000 miles)ll
Steering system for looseness
or damage Inspect every 5,000 km (3,000 miles)l
Universal joints and sleeves Inspect for wear and lubricate every 7,500 km (4,500 miles)ll
Transmission with MT Change every 20,000 km (12,000 miles)
transfer case oil after changing at initial 10,000 km (6,000 miles)l
Transmission :
AT
Change every 32,000 km (20,000 miles) lll l
Transfer:
TF Change every 20,000 km (12,000 miles)
after changing at initial 10,000 km (6,000 miles)l
Differential oil Change every 20,000 km (12,000 miles)
after changing at initial 5,000 km (3,000 miles) l
Disc brake pads and discs Inspect every 5,000 km (3,000 miles)lll
Timing belt G : Replace every 120,000 km (75,000 miles)ll
EXPLANATION OF COMPLETE VEHICLE MAINTENANCE SCHEDULE
Explanations of the services listed in the proceeding
Maintenance Scheduled are presented in ÒService
InformationÓ section of each manual.Replace all questionable parts and note any
necessary repairs as you perform these
maintenance procedures.
MAINTENANCE SCHEDULE UNDER SEVERE DRIVING CONDITIONS
Severe driving conditions
A: Repeated short trips
B: Driving on rough roads
C: Driving on dusty roads
D: Driving in extremely cold weather and/or salted roads

00 – 6 SERVICE INFORMATION
Problem Possible Cause Correction
GENERAL TROUBLESHOOTING (CONT.)
Wandering or Poor
Steering Stability
Erratic Steering When
Bracking
Low or Uneven Trim
Height
Suspension Bottoms
Body Leans
Cupped Tires1. Mismatched or unevenly worn tires.
2. Loose steering linkage ball joints.
3. Faulty shock absorbers.
4. Loose stabilizer bar.
5. Broken or sagging springs.
6. Steering gear misadjustment.
7. Improper wheel alignment.
1. Worn wheel bearings.
2. Broken or sagging springs.
3. Leaking caliper.
4. Warped discs.
5. Badly worn brake pads.
6. Tires are inflated unequally.
1. Broken or sagging springs.
2. Vehicle overloaded.
3. Incorrect springs.
1. Vehicle overloaded.
2. Faulty shock absorber.
3. Incorrect, broken or sagging springs.
1. Loose stabilizer bar.
2. Faulty shock absorbers, struts or
mounting.
3. Broken or sagging springs.
4. Vehicle overloaded.
1. Worn wheel bearings.
2. Excessive tire or wheel runout.
3. Worn ball joints.
4. Tire out of balance.Replace tire or inflate tires to
proper pressure.
Replace ball joints.
Replace shock absorber.
Tighten or replace stabilizer bar
or bushings.
Replace spring (pairs).
Check or adjust steering gear.
Adjust wheel alignment.
Replace wheel bearings.
Replace spring (pairs).
Repair or replace caliper.
Replace brake disc.
Replace brake pads.
Inflate tires to proper pressure.
Replace springs (In pairs)
Reduce load.
Adjust or replace torsion bar.
Reduce load.
Replace shock absorber.
Replace springs.
Tighten stabilizer bar bolts or
replace bushings.
Replace shock absorber.
Replace springs (In pairs)
Reduce load.
Replace wheel bearings.
Replace tire or wheel.
Replace ball joints.
Adjust tire balance.

4C±10
DRIVE SHAFT SYSTEM
8. Remove lock washer and lock screw.
9. Use wrench 5±8840±2117±0, remove hub nut.
411RW005
10. Remove hub and disc assembly.
11. Remove ABS sensor ring (If equipped).
12. Remove outer bearing.
13. Remove oil seal.
14. Remove inner bearing.
15. Remove bolt , if necessary, replace the wheel pin in
the following manner.

Apply a scribe mark(1) to disc to hub.

Clamp the hub and disc assembly in a vise, using
protective pads. Remove the 6 disc±to±hub
retaining bolts.
411RS003

Place hub on a suitable work surface and remove
the studs by using a hammer.
411RS004
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal conditions are
found through inspection.
Check the following parts:

Hub

Hub bearing oil seal

Knuckle spindle

Disc

Caliper

Shift on the fly system parts (Cap, Hub flange, Shim,
Snap ring)

ABS sensor ring (If equipped)
For inspection and servicing of disc caliper and related
parts, refer to Brakes section.

5C – 2 POWER ASSISTED BRAKE SYSTEM
Front Disc Brakes ........................................................................................................... 5C-47
Brake Pads Replacement .......................................................................................... 5C-47
Caliper Replacement ................................................................................................. 5C-50
Rebuilding the Caliper ............................................................................................... 5C-53
Rear Disc Brakes ............................................................................................................ 5C-56
Brake Pads Replacement .......................................................................................... 5C-56
Caliper Replacement ................................................................................................. 5C-59
Rebuilding the Caliper ............................................................................................... 5C-62
Unit Repair .......................................................................................................................... 5C-65
Master Cylinder .............................................................................................................. 5C-65
Vacuum Booster ............................................................................................................. 5C-67
SERVICE PRECAUTION
WARNING:
IF SO EQUIPPED WITH A SUPPLEMENTAL RESTRAINT SYSTEM (SRS), REFER TO THE SRS COMPONENT
AND WIRING LOCATION VIEW IN ORDER TO DETERMINE WHETHER YOU ARE PERFORMING SERVICE ON
OR NEAR THE SRS COMPONENTS OR THE SRS WIRING. WHEN YOU ARE PERFORMING SERVICE ON OR
NEAR THE SRS COMPONENTS OR THE SRS WIRING, REFER TO THE SRS SERVICE INFORMATION.
FAILURE TO FOLLOW WARNINGS COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT, PERSONAL
INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION:
Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact
part number for that application. ISUZU will call out those fasteners that require a replacement after
removal. ISUZU will also call out the fasteners that require thread lockers or thread sealant. UNLESS
OTHERWISE SPECIFIED, do not use supplemental coatings (Paints, greases, or other corrosion inhibitors)
on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener
torque and the joint clamping force, and may damage the fastener. When you install fasteners, use the
correct tightening sequence and specification. Following these instructions can help you avoid damage to
parts and systems.

POWER ASSISTED BRAKE SYSTEM 5C – 5
TROUBLESHOOTING
Condition Possible Cause Correction
Brake Pull1. Tire inflation pressures unequal. 1. Adjust
2. Front wheel alignment incorrect. 2. Adjust
3. Unmatched tires on same axle. 3. Tire with approx. the same amount of
tread should be used on the same axle.
4. Restricted brake pipes or hoses. 4. Check for soft hoses and damaged
lines. Replace with new hoses and new
double-walled steel brake piping.
5. Water or oil on brake pads. 5. Clean or replace.
6. Brake pads hardened. 6. Replace.
7. Brake pads worn excessively. 7. Replace.
8. Brake rotor worn or scored. 8. Grind or replace.
9. Disc brake caliper malfunctioning. 9. Clean or replace.
10. Front hub bearing preload incorrect. 10. Adjust or replace.
11. Loose suspension parts. 11. Check all suspension mountings.
12. Loose calipers. 12. Check and tighten bolts to specifications.
Brake 1. Excessive lateral runout. 1. Check per instructions.
Roughness-orIf not within specifications, replace or
Chattermachine the rotor.
(Pulsates)2. Parallelism not within specifications. 2. Check per instructions.
If not within specifications, replace or
machine the rotor.
3. Wheel bearings not adjusted. 3. Adjust wheel bearings to correct
specifications.
4. Pad reversed (steel against iron). 4. Replace brake pad and machine rotor
to within specifications.
Excessive 1. Malfunctioning vacuum booster. 1. Check vacuum booster operation and
Pedal repair, if necessary.
Effort2. Partial system failure. 2. Check front and rear brake system for
failure and repair. Also, check brake
warning light. If a failed system is
found, the light should indicate a
failure.
3. Excessively worn pad. 3. Check and replace pads in sets.
4. Piston in caliper stuck or sluggish. 4. Remove caliper and rebuild.
5. Fading brakes due to incorrect pad. 5. Remove and replace with original
equipment pad or equivalent.
6. Vacuum leak to vacuum booster. 6. Check for ruptured or loose hose.
7. Check direction of check valve within 7. Correct vacuum hose direction.
vacuum hose.
8. Grease on the brake pads. 8. Replace or clean.
Excessive 1. Air in hydraulic circuit. 1. Bleed hydraulic circuit.
Brake Pedal 2. Level of brake fluid in resevoir too low. 2. Replenish brake fluid resevoir to
Travelspecified level and bleed hydraulic
circuit as necessary.
3. Master cylinder push rod clearance 3. Adjust.
excessive.
4. Leakage in hydraulic system. 4. Correct or replace defective parts.

5C – 6 POWER ASSISTED BRAKE SYSTEM
Condition Possible Cause Correction
Brake Drag1. Master cylinder pistons not returning 1. Adjust stop light switch and vacuum
correctly. booster operating rod. If necessary,
rebuild.
2. Restricted brake pipes or hoses. 2. Check for soft hoses or damaged pipes,
and replace with new hoses and new
double-walled steel brake piping.
3. Parking brake maladjusted. 3. Adjust.
4. Parking brake lining clearance 4. Adjust.
insufficient.
5. Brake pedal free play insufficient. 5. Adjust brake pedal height or power
cylinder operating rod.
6. Piston in master cylinder sticking. 6. Replace.
7. Piston in disc brake caliper sticking. 7. Replace piston seals.
8. Brake pads sticking in caliper. 8. Clean.
9. Return spring weakened. 9. Replace.
10. Parking brake binding. 10. Overhaul parking brakes and correct.
11. Front hub bearing preload incorrect. 11. Adjust or replace.
12. Parking brake shoes not returning. 12. Correct or replace brake back plate and
brake shoe as necessary.
13. Obstructions in hydraulic circuit. 13. Clean.
14. Rotor warped excessively. 14. Grind or replace.
15. Rear brake drum distorted. 15. Grind or replace.
16. Parking cable sticking. 16. Clean or replace.
Grabbing or1. Malfunctioning vacuum booster. 1. Check operation and correct as
Uneven necessary.
Braking Action 2. Binding brake pedal mechanism. 2. Check and lubricate, if necessary.
(All conditions3. Corroded caliper assembly. 3. Clean and lubricate.
listed under
“Pulls”)
Brake Noisy1. Brake pads worn. 1. Replace.
2. Brake pads hardened. 2. Replace.
3. Brake pads in poor contact with rotor. 3. Correct.
4. Brake disc(s) warped, worn or 4. Grind or replace.
damaged.
5. Disc brake anti-squeak shims fatigued. 5. Replace.
6. Front hub bearings loose or preload is 6. Adjust or replace.
incorrect.
7. Brake disc rusted. 7. Grind or replace.
Poor Brake1. Master cylinder faulty. 1. Correct or replace.
Action2. Vacuum booster faulty. 2. Correct or replace.
3. Level of brake fluid in reservoir too 3. Replenish and bleed.
low.
4. Air in hydraulic circuit. 4. Bleed.
5. Disc brake caliper faulty. 5. Clean or replace.
6. Water or oil on brake pads. 6. Clean or replace.
7. Brake pads in poor contact with rotor. 7. Correct.
8. Brake pads worn. 8. Replace.
9. Brake disc rusted. 9. Grind or replace.
10. Check valve in vacuum hose faulty. 10. Correct or replace.

5C – 14 POWER ASSISTED BRAKE SYSTEM
CHECKING BRAKE PEDAL TRAVEL
1. Pedal height (L3) must be measured after starting
the engine and removing it several times to apply
vacuum to the vacuum booster fully.
NOTE:
Pedal height (L3) must be 100 mm (3.9 in)/85 mm (3.5
in) (LHD/RHD) or more when about 50 kg (110.25 lb)
of stepping force is applied.
2. If the measured value is lower than the above
range, air existing in the hydrauic system is
suspected and perform bleeding procedure.
FRONT AND REAR DISC BRAKE PADS
INSPECTION
Check the outer pad by looking at each caliper from
above. Check the thickness on the inner pad by
looking down through the inspection hole in the top of
the caliper. Whenever the pad is worn to about the
thickness of the pad base, the pad should be removed
for further measurements. The pad should be
replaced anytime the pad thickness (t) is worn to
within 1.0 mm (0.039 in) of the pad itself.
The disc pads have a wear indicator that makes a
noise when the pad wears to where replacement is
required.
Minimum Limit mm (in)
1.0 (0.039)
SERVICING THE FRONT BRAKE ROTOR
In the manufacturing of the front brake rotor, all the
tolerances regarding surface finish, parallelism and
lateral runout are held very closely. The maintenance
of these tolerances provide the surface necessary to
assure smooth brake operation.
LATERAL RUNOUT
Lateral runout is the movement of the rotor from side
to side as it rotates on the spindle. This could also be
referred to as “rotor wobble”.
This movement causes the piston to be knocked back
into its bore. This results in additional pedal travel and
a vibration during braking.
t