1995 ISUZU TROOPER Workshop Manual

REFINISHING BRAKE ROTORS (Fig. 5A2-38)
Accurate control of the rotor tolerances is necessary
for proper performance of the disc brakes. Machining
of the rotor should be done only with precision
equipment.
All brake rotors have a minimum thickness
dimension cast into them. This dimension is the
minimum wear dimension and not a refinish
dimension. The
minimum wear dimension is 16.6 mm
(0.654 in). The refinish dimension is 16.97 mm
(0.668 in).
When refinishing rotors,
always use sharp cutting tools
or bits. Dull or worn tools leave a poor surface finish
which
will affect initial braking performance. Vibration
dampening attachments
should always be used when
refinishing braking surfaces. These attachments
eliminate tool chatter and will result in better surface
finish.
After refinishing, replace any rotor does not meet the
minimum thickness of 16.97 mm (0.668 in). Do not use
a brake rotor
that will not meet the specification.
~ Minimum wear
dimension mm (in) 16.6 (0.654)
Refinish dimension
mm (in) 16.97 (0.668)
I W.l.
I

~t
l t"
Fig. 5A2-38
DISC BRAKES 5A2-13
Rear Drum (in Disc) Inside Diameter Check
(Fig. 5A2-39)
Check the rear drum inside diameter by mesuring at
more than
two portions as shown in Fig. 5A2-39.
If the inside diameter is greater than the limit, replace
the rear rotor.
Rear Drum
Inside Diameter
lt!l Standard
Limit mm (in)
mm (in)
Fig. 5A2-39
210.0 (8.27)
211.4 (8.32)

5A2-14 DISC BRAKES
CALIPER REPLACEMENT
6
3
Fig. 5A2-40
1••1 REMOVAL
• Raise the vehicle and support with suitable
safety stands.
1. Wheel and tire assembly
• Refer to "Wheels and Tires" in Section 3E.
2. Brake flexible hose (Fig. 5A2-41)
• Remove the bolt and gaskets, then disconnect
the flexible hose
from the caliper.
• After disconnecting the flexible hose, cap or
tape the openings to prevent entry of foreign
material.
• Since the brake fluid flows out from the
connecting
coupler, place a drain pan under
the
vehicle.
1
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.
*;Repair kit
Fig. 5A2-41

3. Lock bolt (Fig. 5A2-42)
4.
Guide bolt (Fig. 5A2-42)
Fig. 5A2-42
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
1••1 INSTALLATION
8. Clip (Fig. 5A2-43)
Fig. 5A2-43
7. Pad assembly with shim (Fig. 5A2-44)
r;::;:] • Apply special grease (approx. 0.2g) to both
D contacting surfaces of inner shims. Wipe off
extruded grease after installing.
DISC BRAKES 5A2-15
Inner shim
0
Wear indicator
Fig. 5A2-44
6. Support bracket (Fig. 5A2-45)
~~~ Torque N·m (lb·ft) I 148 (109)
Fig. 5A2-45
5. Caliper assembly
4. Guide bolt (Fig. 5A2-46)
3. Lock bolt (Fig. 5A2-46)
~~~ Torque N·m (lb·ft) I
Fig. 5A2-46
44 (32)

5A2-16 DISC BRAKES
2. Brake flexible hose (Fig. 5A2-47)
• Always use new gaskets.
• Be sure to put the hooked edge of the flexible
hose end into the anti-rotation cavity.
~~~ Torque N-m (lb·ft) 35 (26)
Hooked edge
Fig. 5A2-47
1. Wheel and tire assembly
• Refer to "Wheels and Tires" in Section 3E.
• Bleed brakes. Refer to "Hydraulic Brakes" in
Section 5A.
•

DISC BRAKES 5A2-17
REBUILDING THE CALIPER
*3~ Disassembly steps
1. Guide
bolt
*7
9
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
*;Repair kit
Fig. 5A2-48
l•!•l DISASSEMBLY
1. Guide bolt
2. Lock bolt
3. Dust boot
4. Dust boot ring (Fig. 5A2-49)
• Using a small screwdriver, remove the dust
boot ring.
Fig. 5A2-49
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 (Fig. 5A2-50).
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.
\f7 CAUTION:
VI Use just enough air to ease the piston out of the
bore.
If the piston is blown out, it may be
damaged.
Fig.
5A2-50
6. Dust boot; piston
7. Piston seal
8. Bleeder with cap
9.
Caliper body

5A2-18 DISC BRAKES
(1!] 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
• Slide
pin
• Support bracket
NOTE:
The piston dust seal and dust boot are to be replaced
each time the caliper is overhauled. Discard these
used rubber parts and
replace with new ones.
1•! .. 1 REASSEMBLY
9. Caliper body
8. Bleeder with cap
1~1 Torque N·m (lb·in) 8 (69)
7. Piston seal (Fig. 5A2-51)
r:::;] • Apply special rubber grease to the piston seal
D and cylinder wall, then insert the piston seal
into the cylinder. The special rubber grease is
included in the repair kit.
Fig. 5A2-51
5. Piston
6. Dust boot; piston (Fig. 5A2-52)
• 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 (Fig. 5A2-53)
r:::;] • Apply special grease (Approx. 1 g) to the piston
D and attach the dust boot to the piston and
caliper. Insert the dust boot ring into the dust
boot. Fig.
5A2-52
Fig. 5A2-53
3. Dust boot (Fig. 5A2-54)
r:::;] • Install the dust boot on the support bracket
D 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.
2. Lock bolt
1. Guide bolt
Fig. 5A2-54
~~~ Torque N-m (lb·ft) 44 (32)
•