1997 ISUZU TFS SERIES height

5-26 BRAKES
ADJUSTMENT PROCEDURE OF BRAKE PEDAL
The push rod serves as the brake pedal stopper when the
pedal is fully released.
Brake pedal height adjustment should be performed as follows.
Brake Pedal - Height
Measure the brake pedal height after making sure the pedal is
fully returned by the pedal return spring.
Note:
Pedal height (L2) must be measured after starting the
engine and increasing the revolution several times by
stepping on the accelerator pedal.
mm(in)
Pedal free play (L1) 6-10 (0.23 - 0.39)
LHD 174-184 (6.85-7.24)
RHD 193-203 (7.60 7.99)Height (L2)
Note:
Pedal free play must be measured after turning off the
engine and stepping on the brake pedal firmly five times or
more.
If the measured value deviates from the above range, adjust
the brake pedal as follows:
a) Disconnect the stop lamp switch.
b) Loosen the lock nut on the push rod.
c) Adjust the brake pedal to the specified height by rotating the
push rod in the appropriate direction.

BRAKES 5-27
Lock Nut Torque Nm(kgfm/lbft)
15- 25 (1.5 - 2.5 / 11 - 18)
d) Install the stop lamp switch.
Note:
Pedal height (L
2) must be 95 mm (3.7 in.) or more when
applying about 50 kg (110.25 lbs.) of stepping force.
Clearance
Between the Switch Housing and the Brake Pedal (A).
mm(in)
0.5 - 1.0 (0.02 - 0.04)

BRAKES 5-67
TROUBLESHOOTING
Condition and Cause Correction
Poor Brake Action
Master cylinder faulty Correct or replace
Power cylinder faulty Correct or replace
Level of brake fluid in reservoir too low Replenish and bleed
Air in hydraulic circuit Bleed
Front disc brake caliper faulty Clean or replace
Rear brake wheel cylinder faulty Clean or replace
Water or oil on brake pads or linings Clean or replace
Brake pads or linings hardened Replace
Brake pads or linings in poor contact with rotor or brake drum Correct
Brake pads or linings worn Replace
Brake disc or drum rusted Grind or replace
Check valve in vacuum hose faulty Correct or replace
Brake Squeak
Brake pads or linings worn Replace
Brake pads or linings hardened Replace
Brake pads or linings in poor contact with rotor or brake drum Correct
Brake disc(s) warped, worn or damaged Grind or replace
Disc brake anti-squeak shims fatigued Replace
Front hub bearings loose or preload is incorrect Adjust or replace
Brake disc or drum rusted Grind or replace
Brake Pull
Tire inflation pressures unequal Adjust
Front wheel alignment incorrect Adjust
Water or oil on brake pads or linings Clean or replace
Brake pads or linings hardened Replace
Brake pads or linings worn excessively Replace
Brake drum or rotor worn or scored Grind or replace
Front or rear wheel cylinder or disc brake caliper malfunctioning Clean or replace
Front hub bearing preload incorrect Adjust or replace
Brake pad or lining clearances unequal Adjust or replace
Brake Drag
Parking brake maladjusted Adjust
Brake pad or lining clearance insufficient Adjust
Brake pedal free play insufficient Adjust brake pedal height or power cylinder operating rod
Piston in master cylinder sticking Clean or replace
Pistons in disc brake caliper sticking Replace piston seals
Pistons in rear brake wheel cylinders sticking Clean or replace
Brake pads sticking in caliper Clean
Return springs weakened Replace
Parking brake binding Overhaul rear brakes
Front hub bearing preload incorrect Adjust or replace
Rear brake shoes not returning Correct or replace brake back plate, check automatic adjuster and
replace as necessary
Obstructions in hydraulic circuit Clean
Rotor warped excessively Grind or replace
Rear brake drum distorted Grind or replace
Piston cups swollen Replace brake fluid and piston cups
Check valve ; vacuum hose faulty Replace
Parking cable sticking Clean or replace
Rear disc brake over adjust Adjust or overhaul rear brakes
Excessive Brake Pedal Travel
Air in hydraulic circuit Bleed hydraulic circuit
Level of brake fluid in reservoir too low Replenish brake fluid reservoir to specified level and bleed hydraulic
circuit as necessary.
Master cylinder push rod clearance excessive Adjust
Leakage in hydraulic system Correct or replace defective parts
Rear disc brake autoadjuster malfunction Overhaul rear brakes

CAB 10-21
13.Window Glass
First, align the height of regulator to the access hole.
Remove 2 screws attaching bottom channel and
regulator, then remove the glass.
Remove the window glass by tilting it as necessary.
17.Door Lock Assembly
Disconnect the linkage from the door outside handle,
inside lever and lock cylinder.
Remove the 2 bolts holding the outside handle from
inner side.
Remove the 3 bolts holding the door lock assembly.

CAB 10-21
13.Window Glass
First, align the height of regulator to the access hole.
Remove 2 screws attaching bottom channel and
regulator, then remove the glass.
Remove the window glass by tilting it as necessary.
17.Door Lock Assembly
Disconnect the linkage from the door outside handle,
inside lever and lock cylinder.
Remove the 2 bolts holding the outside handle from
inner side.
Remove the 3 bolts holding the door lock assembly.

7C-2 CLUTCH
MAIN DATA AND SPECIFICATIONS
ENGINEHEC Engine
Series with
MSG4JA1HEC Engine
Series with
MUA4JB1T 4JG2T 6VD1
Type Dry single plate with diaphragm
Size mm(in) 215 (8.465) 225 (8.858) 240 (9.449) 250 (9.843) 260 (10.24)
Clamping force kg(lb) 500 (1103) 500 (1103) 560 (1235) 640 (1411) 735 (1621)
(N) (4903) (4903) (5492) (6276) (7208)
Pressure plate
Outside diameter mm(in) 215 (8.465) 225 (8.858) 240 (9.449) 250 (9.843) 260 (10.24)
Inside diameter mm(in) 150 (5.906) 154 (6.063) 160 (6.299) 160 (6.299) 170 (6.70)
Driven plate
Thickness mm(in)
at free 8.4 (0.331) 8.6 (0.339) 8.0 (0.315) 8.2 (0.323) 8.3 (0.327)
at compressed 8.0 (0.315) 7.8 (0.307) 8.0 (0.315) 7.8 (0.307) 8.0 (0.315) 8.0 (0.315)
CLUTCH CONTROL LHD RHD
Type Hydraulic
Pedal free play mm(in) 5.0-15.0 (0.2-0.6)
Pedal height mm(in)
4JG2T 185.5-195.5 (7.30-7.70)
Others 178-188 (7.01-7.40) 216-226 (8.50-8.90)
Master cylinder
BoreStroke mm(in) 15.8735 (0.6251.38)
Slave cylinder
BoreStroke mm(in)
HEC Engine Series for
LHD/4JA120.6416 (0.8130.63)
HEC Engine Series for
RHD/4JB1T/4JG2T22.2215 (0.8750.59)
6VD1 22.2217 (0.8750.67)

CLUTCH 7C-13
SERVICING
Servicing refers to general maintenance procedures to be performed by qualified service personnel.
CLUTCH PEDAL HEIGHT
Inspection
Measure to verify that the distance from the upper surface of
the pedal pad to the firewall is within the standard value.
Clutch Pedal Height(H) mm(in)
RHD LHD
HEC ENGINE216-226
(8.50-8.89)178-188
(7.01-7.40)
4JG2T ENGINE185.5-195.5
(7.30-7.70)
OTHER ENGINE203-213
(7.99-8.39)178-188
(7.01-7.40)
Adjustment
1. Loosen clutch master cylinder push rod lock nut
2.
Turn push rod

1 by hand to set clutch pedal height (H) to
within specification.
2. After the adjustment, tighten lock nut

2.
3. Turn the clutch switch

3 or stopper bolt
3 until the switch
bolt

3 or stopper bolt
3 just touches the clutch pedal arm.
Adjust clutch switch

3 or stopper bolt
3 by backing it out
half a turn, and measure the clearance (L) between the
clutch pedal arm and the clutch switch bolt end

3 or
stopper bolt

3.
Lock the lock nut

4.
Connect clutch switch connector.
Clutch switch and clutch pedal
Clearance mm(in)
(L) 0.5-1.5 (0.020-0.059)
CLUTCH PEDAL PLAY
Inspection
Depress the clutch pedal lightly by hand, and measure to
determine if the free play is within the standard value.
Pedal Free Play mm(in)
H1 5.0-15.0 (0.2-0.6)

7C-22 CLUTCH
Diaphragm Spring Finger Height
(Except 6VD1)
1. Place the appropriate spacer beneath the pressure plate.
Refer to the table below.
Spacer Thickness mm(in)
HEC, 4JG2T 8.0 (0.315)
4JA1, 4JB1T 7.8 (0.307)
2. Fully compress the pressure plate and the diaphragm
spring.
There are two ways to do this.
1) Use a bench press to press down the assembly from the
top.
2) Tighten the fixing bolts.
3. Measure the spring finger height

A from the base to the
spring tip.
Spring Finger Height mm(in)
HEC MSG 37-39
HEC MUA 39.9-41.9
4JA1 30.5-32.5 (1.20-1.28)
4JB1T 35.0-37.0 (1.38-1.46)
4JG2T 39.0-41.0 (1.53-1.61)
6VD1Diaphragm Spring Finger Height (6VD1)
1. Place a new driven plate or a 8.0 mm (0.315 in) spacer
beneath the pressure plate.
2. Fully compress the pressure plate and diaphragm spring.
There are two ways to do this.
1) Use a bench press to press down on the assembly from
the top.
2) Tighten the fixing bolts.
NOTE: (6VD1)
Pre-load on diaphragm spring finger must be 49 - 98N (5.0
- 10.0 kg / 11 - 22 lb) in direction of release, when clutch
cover assembly is bolted to the flywheel.
3. Measure the spring height from base to spring tip
A.
If the measured value exceeds the specified limit, the
pressure plate assembly must be replaced.
Spring Finger Height mm(in)
Standard
6VD1 49.9-51.9 (1.965-2.043)