1997 ISUZU TFS SERIES brake

5-32 BRAKES
Installation Steps
1. Clip ; Pad
2. Pad Assembly with Shim
After attaching the pad assembly with the shim to the support
bracket, position the wear indicator to the lower side of the pad.
3. Caliper Assembly
Lower the caliper into its original position.
Do not damage the flexible hose by twisting or pulling it.
4. Lock Bolt
Attach the lock bolt to the caliper.
Torque N
m(kgfm/lbft)
27 - 37 (2.8 - 3.8 / 20 - 27)

BRAKES 5-33
DISASSEMBLY
CALIPER ASSEMBLY
Disassembly Steps
1. Sleeve
2. Dust boot ; sleeve
3. Dust boot ; guide pin
4. Bleeder with cap
5. Dust seal ring6. Dust seal ; piston
7. Piston (with seal ring)
8. Ring seal
9. Body ; caliper

5-34 BRAKES
Important Operations
5. Dust Seal Ring
Using a small screwdriver, remove the dust boot.
7. Piston (with Ring Seal)
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 tor removal of dust seal.
CAUTION:
Do not place your fingers in front of the piston in an
attempt to catch or protect it when applying compressed
air.

BRAKES 5-35
INSPECTION AND REPAIR
Make necessary correction or parts replacement if wear damage or any other abnormal conditions are found
through inspection.
Rotor
Caliper body
Cylinder bore
Piston
Support bracket
Lock bolt
Guide pin
Visual Check
Inspect the following parts for wear, bending, distortion,
cracking, corrosion, or other abnormal conditions.
Rotor
Thickness (t) mm(in)
Standard Minimum
thickness after
refinishingReplacement
thickness
(Discard)
22.0(0.866) 20.97(0.826) 20.6(0.811)
Run out
Limit mm(in)
0.13 (0.005)
Before inspection, adjust the wheel bearing correctly.
Using a dial gauge, measure the run out at the center of disc
pad contact surface.
Parallelism (Total circumferential thickness variation)
Limit mm(in)
0.15 (0.0006)
Contact surface must be within 0.015 mm at the circumference
of 203 mm dia. Circle.

5-36 BRAKES
Thickness of Disc Pad
Thickness (t) mm(in)
Standard Limit
10.5 (0.413)
9.5 (0.374)
(For Australia only)1.0 (0.039)
Replace the front disc pad whenever the pad wear indicator
makes a squeaking noise or when the pad is worn to within 1
mm of the shoe table.
All four brake pads should be replaced together.
Seal and Boot
The dust seal, dust boot and ring seal are to be replaced each
time the caliper is overhauled.
Discard thee used rubber parts.

BRAKES 5-37
REASSEMBLY
CALIPER ASSEMBLY
Disassembly Steps
1. Body ; caliper
2. Ring seal
3. Piston
4. Dust seal ; piston
5. Dust seal ring
6. Dust boot ; sleeve
7. Dust boot ; guide pin
8. Sleeve
9. Bleeder with cap
Important Operations
1. Body ; Caliper
2. Ring Seal
Apply special grease to the ring seal and cylinder wall, then
insert the ring seal into the cylinder.
The special grease is included in the repair kit.

5-38 BRAKES
3. 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 ring seal can result.
4. Dust Seal ; Piston
5. Dust Seal Ring
Apply special grease (Approx. 1g) to the piston and attach the
dust seal to the piston and caliper.
Insert the dust seal ring into the dust seal.
6. Dust Boot ; Sleeve
7. Dust Boot ; Guide Pin
Install the sleeve dust boot on the caliper after applying special
grease (Approx. 1g) into the sleeve and guide pin boot, then
insert the sleeve into the dust boot.
9. Bleeder with Cap
Torque N
m(kgfm/Ibft)
5.9-8.8 (0.6 - 0.9 / 4.3 - 6.5)

BRAKES 5-39
REAR DRUM BRAKE ASSEMBLY
DISASSEMBLY
First, disassemble the brake drum. Then disassemble the rear brake assembly.
Refer to the “REAR AXLE” section for the brake drum disassembly procedure.
MAJOR COMPONENTS
Disassembly Steps
1. Brake line
2. Holding spring and cups
3. Return spring ; lower
4. Return Spring ; upper
(shoe to adjust lever)
5. Return spring ; upper
(shoe to shoe)
6. Shoe assembly (primary)7. Shoe assembly with lever
8. Retainer with pin
9. Washer ; wave
10. Lever ; auto adjust
11. Shoe assembly (secondary)
12. Adjuster assembly
13. Wheel cylinder assembly
MINOR COMPONENTS
Disassembly Steps
Wheel Cylinder Assembly (13)
14. Boot ; wheel cylinder
15. Piston assembly
16. Cup ; piston17. Return spring ; piston
18. Bleeder ; wheel cylinder