1997 ISUZU TFS SERIES Workshop Manual

BRAKES 5-41
Free length
mm(in.)Set length
mm(in.)Set load
kg(lbs.)
Return spring :
upper
(adjust lever)124.9
(4.917)134.9
(5.311)70.7
(15.4
1.6)
Shoe return
spring : upper112.4
(4.425)121.5
(4.783)20.2
(4.4
0.4)
Shoe return
spring : lower167.2
(6.583)190.2
(7.488)28.02.8
(61.7
6.4)
Clean wheel Cylinder Parts
Always use clean brake fluid to clean wheel cylinder parts.
Note:
Do not use mineral-vase cleaning solvents such as
gasoline, kerosene, acetone, paint thinner, or carbon
tetrachloride.
Clearance Between the Wheel Cylinder
and the Piston
mm(in)
Standard Limit
0.02 - 0.1(0.001 - 0.004) 0.15(0.006)
Piston Cups
Inspect the piston cups for wear, distortion, fatigue, fatigue or
other abnormal conditions.
Measuring the Brake Drum
mm(in)
Standard Limit
Inside diameter 254(10.000) 255.5(10.059)
Run out 0.05(0.002) 0.15(0.006)
Inside diameter 295(11.614) 296.5(11.673)
Run out 0.05(0.02) 0.15(0.006)TFS
TFR

5-42 BRAKES
REASSEMBLY
MINOR COMPONENTS
Reassembly Steps
Wheel cylinder Assembly (7)
1. Bode ; wheel cylinder
2. Return spring ; piston
3. Cup ; piston4. Piston assembly
5. Boot ; wheel cylinder
6. Bleeder ; wheel cylinder
MAJOR COMPONENTS
Reassembly Steps
7. Wheel cylinder assembly
8. Adjuster assembly
9. Shoe assembly (secondary)
10. Lever ; auto adjuster
11. Washer ; wave
12. Retainer with pin
13. Shoe assembly (primary)14. Return spring ; upper
(shoe to shoe)
15. Return spring ; upper
(shoe to adjust lever)
16. Return spring ; lower
17. Holding spring and cups
18. Brake line

BRAKES 5-43
Important Operations
1. Bode ; Wheel Cylinder
Lubricate the cylinder bore with clean rubber grease.
4. Piston Assembly
Install new piston cups on each piston so that the flared end of
the cups are turned to the inboard side of the pistons.
Attach the return spring and the boot to the piston.
Apply DELCO silicone lube No.5459912 (or equivalent) to the
piston and the inner face of the boots.
6. Bleeder ; Wheel Cylinder
Torque N
m(kgfm/Ibft)
6.9 - 11.8 (0.7 - 1.2 / 5.1 - 8.7)
7. Wheel Cylinder Assembly
Torque N
m(kgfm/Ibft)
11 - 15 (1.1 - 1.5 / 8 - 11)

5-44 BRAKES
18.Brake Line
Torque N
m(kgfm/Ibft)
13 - 19 (1.3 - 1.9 / 9 - 14)
Apply grease lightly to back plate A.

BRAKES 5-45
BRAKE CONTROL
REMOVAL AND INSTALLATION
BRAKE PEDAL ASSEMBLY
This illustration based on the LHD model
Removal Steps
1. Return spring
2. Snap pin
3. Pin ; push rod to pedal
4. Pin ; fulcrum, pedal to bracket
5. Pedal assembly with bush
Installation steps
To install, follow the removal procedure in
reverse order.
Before installation, appyl grease to the entire
circumference of the fulcrum pin (4) and push
rod pin (3).
Refer to "SERVICING" in this section for
adjustment procedure of brake pedal.

5-46 BRAKES
MASTER CYLINDER
REMOVAL AND INSTALLATION
BRAKE PEDAL ASSEMBLY
This illustration based on the LHD model.
Removal Steps
1. Brake line
2. Nut ; master cylinder to vacuum servo
3. Master cylinder assembly
Installation Steps
3. Master cylinder assembly
2. Nut ; master cylinder to vacuum servo
1. Brake line
Important Operation - Removal
1. Brake Line
Be very careful not to spill brake fluid on the painted surface.
Damage to the painted surface will result.
Important Operation - Installation
2. Nut ; Master Cylinder to Vacuum Servo
Torque N
m (kgfm/lbft)
1.0 - 1.6 (7 - 12 / 9.8 - 16)
1. Brake Line
Torque N
m (kgfm/lbft)
0.9 - 1.5 (6.5 - 11 / 8.8 - 15)

BRAKES 5-47
DISASSEMBLY
Disassembly Steps
1. Dust seal
2. Screw
3. Reservoir ; fluid, brake
4. Grommet
5. Ring ; snap
6. Bolt ; stopper7. Gasket
8. Piston assembly ; primary and spring
9. Piston assembly ; secondary and spring
10. Cover ; fluid reservoir
11. Seal
12. Cylinder assembly ; brake, master

5-48 BRAKES
Important Operations
When disassembling, inspecting or reassembling the master
cylinder assembly, take care not to bring the parts into contact
with mineral oil or dust. Wash the piston cups only with brake
fluid. Do not use gasoline or other mineral-base cleaning
solvents.
5. Ring ; Snap
Remove the snap ring from the cylinder body with pushing in
the primary and secondary pistons.
6. Bolt ; Stopper
Push in the primary and secondary pistons and remove the
stopper bolt completery from the cylinder body, then remove
the primary and secondary piston assemblies.
8. Piston Assembly ; Primary and Spring
9. Piston Assembly ; Secondary and Spring
Don’t remove the spring from the piston.