2002 ISUZU AXIOM Service Repair Manual

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Page 737 of 2100

ISUZU AXIOM 2002 Service Repair Manual 5C±57 POWER±ASSISTED BRAKE SYSTEM
Machining The Drum
If a drum is to be machined, only enough metal should be
removed to obtain a true, smooth braking surface. If a
drum does not clean-up when mach

Page 738 of 2100

ISUZU AXIOM 2002 Service Repair Manual 5C±58
POWER±ASSISTED BRAKE SYSTEM
Disassembled View
305RS006
Legend
(1) Boot
(2) Piston Assembly
(3) Piston Cup
(4) Return Spring
(5) Bleeder
(6) Wheel Cylinder
Disassembly
1. Remove boot (1) and pi

Page 739 of 2100

ISUZU AXIOM 2002 Service Repair Manual 5C±59 POWER±ASSISTED BRAKE SYSTEM
3. Install new piston cups (3) on each piston so that the
flared end of the cups are turned to the inboard side of
the pistons.
Attach the return spring (4) and the

Page 740 of 2100

ISUZU AXIOM 2002 Service Repair Manual 5C±60
POWER±ASSISTED BRAKE SYSTEM
Main Data and Specifications
General Specifications
Rear drum brake
TypeLeading-trailing, non-servo
Drum inside diameter295 mm (11.6 in)
Wheel cylinder diameter22.2

Page 741 of 2100

ISUZU AXIOM 2002 Service Repair Manual 5C±61 POWER±ASSISTED BRAKE SYSTEM
AXIOM (Vehicles Produced After Aug./1/2001)
POWER-ASSISTED BRAKE SYSTEM
CONTENTS
Service Precaution 5C±62. . . . . . . . . . . . . . . . . . . . . .
General Descr

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. . . . . . . .

Page 742 of 2100

ISUZU AXIOM 2002 Service Repair Manual 5C±62
POWER±ASSISTED BRAKE SYSTEM
Brake Pads Inspection 5C±101. . . . . . . . . . . . . . . . .
Brake Pads and Associated Parts 5C±101. . . . . . .
Removal 5C±102. . . . . . . . . . . . . . . .

5C±62
POWER±ASSISTED BRAKE SYSTEM
Brake Pads Inspection 5C±101. . . . . . . . . . . . . . . . .
Brake Pads and Associated Parts 5C±101. . . . . . .
Removal 5C±102. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5C±102. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Disc Brake Rotor (4y4 Model) 5C±104. . . . . . . .
Inspection 5C±104. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing Brake Rotors 5C±104. . . . . . . . . . . . . . . .
Refinishing Brake Rotors 5C±104. . . . . . . . . . . . . . .
Rear Drum (In Disc) Inside Diameter
Check 5C±105. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Disc Brake Caliper Assembly
(4y4 Model) 5C±106. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Disc Brake Caliper Assembly and
Associated Parts 5C±106. . . . . . . . . . . . . . . . . . . . . .
Removal 5C±106. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5C±107. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Disc Brake Caliper (4y4 Model) 5C±108. . . . . .
Rear Disc Brake Caliper Disassembled
View 5C±108. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly 5C±109. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 5C±109. . . . . . . . . . . . . . . . . . Reassembly 5C±109. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications
(4y4 Model) 5C±111. . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Lining 5C±112. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Lining and Associated Parts 5C±112. . . . . . .
Removal 5C±112. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Lining Inspection 5C±113. . . . . . . . . . . . . . . .
Installation 5C±113. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drum Brake Adjustment (4y2 Model) 5C±114. . . . .
Servicing The Brake Drum 5C±114. . . . . . . . . . . . . .
Wheel Cylinder Assembly (4y2 Model) 5C±115. . . . .
Wheel Cylinder Assembly and Associated
Parts 5C±115. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 5C±115. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5C±115. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View 5C±116. . . . . . . . . . . . . . . . . . . .
Disassembly 5C±116. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 5C±116. . . . . . . . . . . . . . . . . .
Reassembly 5C±116. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 5C±118. . . . . . . . . . . . .
Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE
SRS
COMPONENT AND WIRING LOCATION VIEW
IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING, REFER TO
THE
SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN POSSIBLE
AIR BAG DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.
General Description
Master Cylinder Assembly
330R200002

Page 743 of 2100

ISUZU AXIOM 2002 Service Repair Manual 5C±63 POWER±ASSISTED BRAKE SYSTEM
The master cylinder contains two pistons that supply the
hydraulic pressure for a dual±circuit braking system. The
primary piston provides the fluid pressure to th

Page 744 of 2100

ISUZU AXIOM 2002 Service Repair Manual 5C±64
POWER±ASSISTED BRAKE SYSTEM
Disc Brake
Front Disc Brake
A05R200001
Rear Disc Brake (4y4 Model)
A05RW002
The disc brake assembly consists of a caliper, piston,
rotor, pad assembly and support b

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