2002 ISUZU AXIOM light

5C±11 POWER±ASSISTED BRAKE SYSTEM
330RW012
17. Bleed the air from the front wheel brake pipe
connection (2) by repeating steps 7 through 16.
Bleeding the Caliper
18. Bleed the air from each wheel in the order listed
below:

Right rear caliper or wheel cylinder

Left rear caliper or wheel cylinder

Right front caliper

Left front caliper
Conduct air bleeding from the wheels in the above
order. If no brake fluid comes out, it suggests that air
is mixed in the master cylinder. In this case, bleed air
from the master cylinder in accordance with steps 7
through 17, and then bleed air from the caliper or
wheel cylinder.
19. Place the proper size box end wrench over the
bleeder screw.
20. Cover the bleeder screw with a transparent tube, and
submerge the free end of the transparent tube in a
transparent container containing brake fluid.
21. Pump the brake pedal slowly three (3) times
(once/sec), then hold it depressed.
22. Loosen the bleeder screw until fluid flows through the
tube.
23. Retighten the bleeder screw.
24. Release the brake pedal slowly.
25. Repeat steps 21 through 24 until the air is completely
removed.
It may be necessary to repeat the bleeding procedure
10 or more times for front wheels and 15 or more
times for rear wheels.
26. Go to the next wheel in the sequence after each wheel
is bled.
Be sure to monitor reservoir fluid level.
27. Depress the brake pedal to check if you feel
ªsponginessº after the air has been removed from all
wheel cylinders and calipers.
If the pedal feels ªspongyº, the entire bleeding
procedure must be repeated.28. After the bleeding operation is completed on the each
individual wheel, check the level of the brake fluid in
the reservoir and replenish up to the ªMAXº level as
necessary.
29. Attach the reservoir cap.
If the diaphragm inside the cap is deformed, reform
it and install.
30. Stop the engine.
Flushing Brake Hydraulic System
It is recommended that the entire hydraulic system be
thoroughly flushed with clean brake fluid whenever new
parts are installed in the hydraulic system. Approximately
one quart of fluid is required to flush the hydraulic system.
The system must be flushed if there is any doubt as to the
grade of fluid in the system or if fluid has been used which
contains the slightest trace of mineral oil. All rubber parts
that have been subjected to a contaminated fluid must be
replaced.
Brake Pipes and Hoses
The hydraulic brake system components are
interconnected by special steel piping and flexible hoses.
Flexible hoses are used between the frame and the front
calipers, the frame and rear axle case and the rear axle
and the rear calipers.
When the hydraulic pipes have been disconnected for
any reason, the brake system must be bled after
reconnecting the pipe. Refer to
Bleeding the Brake
Hydraulic System
in this section.
Brake Hose Inspection
The brake hose should be inspected at least twice a year.
The brake hose assembly should be checked for road
hazard, cracks and chafing of the outer cover, and for
leaks and blisters. Inspect for proper routing and
mounting of the hose. A brake hose that rubs on
suspension components will wear and eventually fail. A
light and mirror may be needed for an adequate
inspection. If any of the above conditions are observed on
the brake hose, adjust or replace the hose as necessary.
CAUTION: Never allow brake components such as
calipers to hang from the brake hoses, as damage to
the hoses may occur.

5C±15 POWER±ASSISTED BRAKE SYSTEM
P & B (Proportioning and Bypass) Valve
P & B (Proportioning and Bypass)
Valve Sectional View
350RW014
Legend
(1) Master Cylinder (Secondary)
(2) Master Cylinder (Primary)
(3) Rear Brake
(4) Front Brake
The P&B valve contains two sections, each serving a
different function.
The proportioning section of the P&B valve proportions
outlet pressure to the rear brakes after a predetermined
rear input pressure has been reached. This is done to
prevent rear wheel lock up on the vehicles with light rear
wheel loads. The valve has a by±pass feature which
assures full system pressure to the rear brakes in the
event of front brake system malfunction. Also full front
pressure is retained in the event of rear brake
malfunction.
The P&B valve is not repairable and must be replaced as
complete assembly.
Removal
1. The P&B valve is not repairable and must be replaced
as a complete assembly. Care must be taken to
prevent brake fluid from contacting any painted
surface.
2. Remove hydraulic pipes (1) and plug the pipes (1) to
prevent the loss of fluid or the entrance of dirt.
3. Remove bolt (3).
4. Remove P&B valve (2).
350RW026
Installation
1. Install P&B valve (2).
2. Install bolt (3) and tighten the bolt to the specified
torque.
Torque: 22 N´m (16 lb ft)
3. Install hydraulic pipes (1) and tighten the bolt to the
specified torque.
Torque: 15 N´m (11 lb ft)
4. After installing the brake pipes, bleed the brakes as
refer to
Bleeding Brake Hydraulic System in this
section.

5C±17 POWER±ASSISTED BRAKE SYSTEM
Brake Pedal
Checking Pedal Height
The push rod serves as the brake pedal stopper when the
pedal is fully released. Brake pedal height adjustment
should be performed as follows:
Adjust Brake Pedal
310RY00004
1. Measure the brake pedal height after making sure the
pedal is fully returned by the pedal return spring.
Pedal height must be measured after starting the
engine and receiving it several times.
Pedal Free Play: 6-10 mm (0.23-0.39 in)
Pedal Free Play: 173-185 mm (6.81-7.28 in)
NOTE: Pedal free play must be measured after turning
off the engine and stepping on the brake pedal firmly five
times or more.
2. If the measured value is not within the above range,
adjust the brake pedal as follows:
a. Disconnect the stoplight switch connector.
b. Loosen the stoplight switch lock nut.
c. Rotate the stoplight switch so that it moves away
from the brake pedal.
d. Loosen the lock nut (1) on the push rod.
e. Adjust the brake pedal to the specified height by
rotating the push rod in the appropriate direction.
f. Tighten the lock nut to the specified torque.
Torque: 20 N´m (15 lb ft)
g. Adjust the stoplight switch (2) to the specified
clearance (between the switch housing and the
brake pedal) by rotating the switch housing.
Clearance: 0.5±1.0 mm (0.02±0.04 in)
310RY00005
NOTE: While adjusting the stoplight switch, make sure
that the threaded part of the stoplight switch does not
push the brake pedal.
h. Tighten the stoplight switch lock nut.
i. Connect the stoplight switch connector.
Checking Pedal Travel
310RY00004
1. Pedal height must be measured after starting the
engine and revving it several times to apply vacuum
to the vacuum booster fully.
NOTE: Pedal height must be 95 mm (3.7 in) 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 may still be present in the hydraulic system
Perform the bleeding procedure.

5C±18
POWER±ASSISTED BRAKE SYSTEM
Brake Pedal and Associated Parts
310RY00006
Legend
(1) Brake Pedal Bracket Assembly
(2) Fulcrum Pin and Nut
(3) Connector
(4) Snap Pin
(5) Return Spring(6) Peadl Assembly
(7) Push Rod Pin
(8) Lower Cover
(9) Bolts and Nut
(10) Driver Knee Bolster
Removal
1. Disconnect the battery ª±º terminal cable, and wait at
least 5 minutes.
2. Disconnect the yellow 3 way SRS connector located
under the steering column.
3. Remove the engine hood opening lever.
4. Remove lower cover (8).
5. Remove driver knee bolster (10).
6. Disconnect the stop light switch connector (3).
Disconnect the anti-theft control module connector.
Refer to
Body and Accessories section in this
Manual.
7. Remove snap pin (4) and push rod pin (7).
8. Remove the steering column shaft fixing bolt and nut
(9) on the steering wheel side, and lower the steering
column shaft.
9. Remove the brake pedal bracket assembly (1).
10. Remove return spring (5).
11. Remove fulcrum pin and nut (2).12. Remove pedal assembly (6).
Installation
1. Apply grease to the entire circumference of the
fulcrum pin.
2. Install pedal assembly (6) and fulcrum pin and nut (2).
Tighten the nut (2) to the specified torque.
Torque: 35 N´m (26 lb ft)
3. Install the brake pedal bracket assembly (1).
Tighten the bolts and nuts soecified torque.
Torque: 15 N´m (11 lb ft)
4. Install return spring (5).
5. Adjust pedal free travel.
Refer to
Brake Pedal Adjustment in this section.
6. Tighten the steering column fixing bolt (9) (dash
panel) to the specified torque.
Torque: 20 N´m (14 lb ft)

5C±19 POWER±ASSISTED BRAKE SYSTEM
7. Tighten the steering column fixing nut (9) (Cross
Beam) to the specified torque.
Torque: 17 N´m (12 lb ft)
8. Apply grease to the entire circumference of the Push
rod pin (7).
9. Install push rod pin (7).
10. Install snap pin (4).
11. Connect the anti-theft control module connector.
Refer to
Body and Accessories section in this
manual.12. Connect the stop light switch connector (3).
13. Install driver knee bolster (10) and lower cover (8).
14. Install the engine hood opening lever.
15. Connect the yellow 3 way SRS connector located
under the steering column.
16. Connect the battery ª±º terminal cable.
Stoplight Switch
Parts Location
310RW008
Legend
(1) Connector
(2) Switch
(3) Lock Nut
Removal
1. Disconnect connector (1)
2. Remove lock nut (3).
3. Remove switch (2).
Installation
1. Adjust the stop light switch to the specified clearance
(between switch housing and brake pedal) by rotating
the switch housing.
Clearance : 0-0.2 mm (0-0.08 in)
NOTE: Do not attempt to force the push rod into position
during the stop light switch installation and adjustment
procedure.
310RY00005
2. Connect connector (1).
3. Install lock nut (3).

5C±55 POWER±ASSISTED BRAKE SYSTEM
NOTE: Do not over stretch the return spring.
305RS003
9. Remove upper (inner) return spring (9).
10. Remove hold-down spring and cup (3) and hold-down
pin (16).
11. Remove Trailing shoe assembly (7) with parking
brake lever (16).
12. Remove parking brake cable from parking brake lever
(11).
13. Remove retainer (14), wave washer (13), and parking
brake lever (11).
Brake Lining Inspection
Check the shoe assemblies for wear by removing brake
drum.
Replace the shoe assemblies, if lining thickness is less
than 1.0 mm (0.039 in).
The shoe assemblies have a wear indicator that makes a
noise when the linings wear to a degree where
replacement is required.
Minimum limit: 1.0 mm (0.039 in)
305RS001
Installation
1. Apply grease lightly to back place A.
305RW002
Legend
(1) Place A (3 portions for each side)
2. Install parking brake lever (11), wave washer (13),
and retainer (14).
3. Install trailing shoe assembly (7) with parking brake
lever (16).
4. Install the parking brake cable to parking brake lever
(11).
5. Install hold-down pin (16) and hold-down spring and
cup (3).
6. Install upper (inner) return spring (9).
7. Install leading shoe assembly (8) with upper (inner)
return spring (9).
NOTE: Do not over stretch the return spring.
305RS003
8. Install adjuster assembly (12).
9. Install hold-down pin (15) and hold-down spring and
cups (4).

5C±56
POWER±ASSISTED BRAKE SYSTEM
10. Install lower return spring (5).

Use brake spring tool.
11. Install auto adjuster lever (10).
12. Install upper (outer) return spring (6).

Use brake spring tool.
13. Install brake drum (2).

Adjust the brakes, refer to
Drum Brake Adjustment
in this section.
14. Install wheel and tire assembly (1).

Refer to
ªWheels and Tires º in wheel and Tire
System
section.
Drum Brake Adjustment (4y2 Model)
NOTE: All brakes are self-adjusting. Brakes are adjusted
by repeated stepping on the brake pedal. (After stepping
on the pedal and releasing it, the rear auto adjuster, in the
rear brake, produces a clicking sound.
The same operation should be repeated until the sound
disappears.)
Take the following steps after overhauling the rear brake
assembly.
1. Move the parking brake handle to its fully released
position.
2. Parking cable must be loosened sufficiently. (Loosen
the adjust nut and the lock nut.)
3. Repeat stepping on the brake pedal firmly, and
releasing it until the clicking sound can no longer be
heard.
If the difference between the brake drum inside
diameter and diameter of the brake shoes is adjusted
to be 0,5 mm, the number of times for depressing the
brake pedal can be reduced.
4. Remove the drum. Measure the brake drum inside
diameter and diameter of the brake shoes.
Shoe clearance: 0.25-0.4 mm (0.0098-0.0157 in)
If incorrect, check the brake auto-adjusting system.
5. Rotate the adjust nut until all slack disappears from
the cable. Set the adjust nut.
6. Applying about 30 kg (66 lb) of force, pull the parking
brake handle to its fully set position three or four
times.
7. If the parking brake is properly adjusted, the travel
between the fully disengaged position and the fully
engaged position will be between 9 and 11 notches.
If the traveling range is not within these limits, again
repeat steps 1 through 5.
After adjusting has been done, check to see if the rear
wheel rotates smoothly without drag when turned by
hand.
Servicing The Brake Drum
Whenever the brake drums are removed, they should be
thoroughly cleaned and inspected for cracks, scores,
deep grooves and out-of-round.
Cracked, Scored or Grooved Drum
A cracked drum is unsafe and must be replaced.
Do not attempt to weld a cracked drum.
Smooth any slight scores. Heavy or extensive scoring will
cause excessive brake lining wear, and it will probably be
necessary to machine the drum braking surface.
If the brake linings are slightly worn and the drum is
grooved, the drum should be polished with fine emery
cloth but should not be machined. At this stage,
eliminating all the grooves in the drum and smoothing the
ridges on the lining would require the removal of too much
metal and lining. If left alone, the grooves and ridges
match and satisfactory service can be obtained. If brake
linings are to be replaced, a grooved drum should be
machined. Using a grooved drum with new linings will
create inefficient braking performance and cause the
linings to wear quicker.
Out-Of-Round Drum
An out-of-round drum makes accurate brake shoe
adjustment impossible and is likely to cause excessive
wear to other parts of the brake mechanism due to its
eccentric action. An out-of-round drum can also cause
severe and irregular tire tread wear as well as a pulsing
brake pedal. When the braking surface of a brake drum
exceeds the specification limit of 0.15 mm (0.006 in) in
out-of-round, the drum should be machined to true up the
braking surface. Out-of-round can be accurately
measured with an inside micrometer fitted with proper
extension rods. When measuring a drum for out-of-round
and wear, take measurements at the open and closed
edges of machines surfaces and at right angles to each
other.
Maximum out-of-round: 0.15 mm (0.006 in)
420RS034

5C±61 POWER±ASSISTED BRAKE SYSTEM
AXIOM (Vehicles Produced After Aug./1/2001)
POWER-ASSISTED BRAKE SYSTEM
CONTENTS
Service Precaution 5C±62. . . . . . . . . . . . . . . . . . . . . .
General Description 5C±62. . . . . . . . . . . . . . . . . . . . .
Diagnosis 5C±66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Diagnosis 5C±67. . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Brakes 5C±70. . . . . . . . . . . . . . . . . . . . . . . .
Filling Master Cylinder Reservoir 5C±70. . . . . . . .
Deterioration of Brake Fluid 5C±70. . . . . . . . . . . . .
Leakage of Brake Fluid 5C±70. . . . . . . . . . . . . . . . .
Bleeding Brake Hydraulic System 5C±70. . . . . . . .
Flushing Brake Hydraulic System 5C±71. . . . . . . .
Brake Pipes and Hoses 5C±71. . . . . . . . . . . . . . . .
Brake Hose Inspection 5C±71. . . . . . . . . . . . . . . . .
Front Caliper Brake Hose 5C±72. . . . . . . . . . . . . . . .
Front Caliper Brake Hose and Associated
Parts 5C±72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 5C±72. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5C±72. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Axle Brake Hose 5C±73. . . . . . . . . . . . . . . . . . .
Rear Axle Brake Hose and Associated
Parts 5C±73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 5C±73. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5C±73. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Pipe 5C±74. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 5C±74. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5C±74. . . . . . . . . . . . . . . . . . . . . . . . . . . .
P & B (Proportioning and Bypass) Valve 5C±75. . . .
Removal 5C±75. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5C±75. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 5C±76. . . . . . . . . . . . .
Brake Pedal 5C±77. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Pedal Height 5C±77. . . . . . . . . . . . . . . . .
Checking Pedal Travel 5C±77. . . . . . . . . . . . . . . . .
Brake Pedal and Associated Parts 5C±78. . . . . . .
Removal 5C±78. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5C±78. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stoplight Switch 5C±79. . . . . . . . . . . . . . . . . . . . . . . . .
Parts Location 5C±79. . . . . . . . . . . . . . . . . . . . . . . .
Removal 5C±79. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5C±79. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 5C±80. . . . . . . . . . . . .
Master Cylinder Assembly 5C±81. . . . . . . . . . . . . . . .
Master Cylinder Assembly and Associated
Parts 5C±81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 5C±81. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 5C±81. . . . . . . . . . . . . . . . . . . . . . . . . . . . Master Cylinder Assembly 5C±82. . . . . . . . . . . . . . . .
Master Cylinder Assembly Desassembled
View 5C±82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Desassembly 5C±82. . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 5C±82. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly 5C±83. . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5C±83. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 5C±84. . . . . . . . . . .
Vacuum Booster Assembly 5C±85. . . . . . . . . . . . . . .
Vacuum Booster Assembly and Associated
Parts 5C±85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 5C±85. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 5C±86. . . . . . . . . . . . . . . . . .
Exterior Components 5C±87. . . . . . . . . . . . . . . . . . . .
Exterior Components and Associated
Parts 5C±87. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 5C±87. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 5C±88. . . . . . . . . . . . . . . . . .
Installation 5C±88. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vacuum Booster Overhaul 5C±88. . . . . . . . . . . . . . . .
Vacuum Booster 5C±88. . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 5C±89. . . . . . . . . . . . .
Front Disc Brake Pads 5C±90. . . . . . . . . . . . . . . . . . .
Front Disc Brake Pads Inspection 5C±90. . . . . . . .
Front Disc Brake Pads and Associated
Parts 5C±90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 5C±91. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5C±91. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Disc Brake Rotor 5C±93. . . . . . . . . . . . . . . . . . .
Inspection 5C±93. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing Brake Rotors 5C±93. . . . . . . . . . . . . . . .
Refinishing Brake Rotors 5C±93. . . . . . . . . . . . . . .
Front Disc Brake Caliper Assembly 5C±95. . . . . . . .
Front Disc Brake Caliper Assembly and
Associated Parts 5C±95. . . . . . . . . . . . . . . . . . . . . .
Removal 5C±95. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5C±96. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Disc Brake Caliper 5C±98. . . . . . . . . . . . . . . . .
Front Disc Brake Caliper Disassembled
View 5C±98. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly 5C±98. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 5C±99. . . . . . . . . . . . . . . . . .
Reassembly 5C±99. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 5C±100. . . . . . . . . . .
Rear Disc Brake Pads (4y4 Model) 5C±101. . . . . . . .