2004 ISUZU TF SERIES section 8A

ANTI-LOCK BRAKE SYSTEM 5B-19

G-Sensor
G-Sensor and Associated Parts


RTW45BLF000101
Legend


1.
G-Sensor


2.
Nut

Removal
1. Remove the front floor console. (Refer to the section
Floor Console)
2. Disconnect the connector.
3. Remove the nuts.
4. Take out the G-sensor.


Installation
1. Set the G-sensor.
2. Install the nut and tighten it to specified torque.

Torque : 8.0 N·m (0.8 kg·m /69 lb in)
3. Connect the connector.
4.
Install the front floor console. (Refer to the
section Floor Console)

BRAKES 5C-1
SECTION 5C
BRAKES
TABLE OF CONTENTS
PAGE
General Description......................................................................................................... 5C- 2
Main Data and Specifications ......................................................................................... 5C- 9
Torque Specifications ..................................................................................................... 5C-10
Servicing........................................................................................................................... 5C-19
Front Brake Assembly ..................................................................................................... 5C-33
Removal and Installation ............................................................................................ 5C-33
Removal and installation of Disc Pad ....................................................................... 5C-37
Disassembly ................................................................................................................ 5C-39
Inspection and Repair................................................................................................. 5C-40
Reassembly ................................................................................................................. 5C-42
Rear Drum Brake Assembly ............................................................................................ 5C-44
Disassembly ................................................................................................................ 5C-44
Inspection and Repair................................................................................................. 5C-45
Reassembly ................................................................................................................. 5C-47
Brake Control ................................................................................................................... 5C-51
Removal and Installation ............................................................................................ 5C-51
Master Cylinder ................................................................................................................ 5C-52
Removal and Installation ............................................................................................ 5C-52
Disassembly ................................................................................................................ 5C-53
Inspection and Repair................................................................................................. 5C-55
Reassembly ................................................................................................................. 5C-56
Vacuum Booster .............................................................................................................. 5C-58
Removal and Installation ............................................................................................ 5C-58

BRAKES 5C-35



6. Support Bracket
Take care not to damage the flexible brake hose when
removing the support bracket.



7. Front Hub and Disc Assembly
For the removal procedure, refer to Section 4C "FRONT
WHEEL DRIVE".



Important Operations - Installation
7. Front Hub and Disc Assembly
For the installation procedure, refer to the front hub and disc
reassembly procedure in Section 4C "FRONT WHEEL
DRIVE".

5C-44 BRAKES
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.

RTW35CMF000201

MAJOR COMPONENTS
Disassembly Steps

1. Spring ; adjuster
2. Ring ; Adjuster lever
3. Lever ; adjuster

4. Spring ; Shoe hold
5. Pin ; Shoe hold

6. Spring ; Shoe to shoe, lower
7. Adjuster assembly
8. Spring ; shoe to shoe, upper
9. Shoe ; leading

10. Shoe ; trailing
11. Spring ; lever return
12. Retainer
13. Washer ; lever
14. Lever ; parking
15. Bolt ; wheel cylinder
16. Wheel cylinder assembly
17. Cover
18. Back plate

MINOR COMPONENTS
Disassembly Steps
Wheel Cylinder Assembly (14)

19. Piston
20. Cup
21. Boot ; piston

22. Return spring
23. Bleeder
24. Cap ; bleeder

BRAKES 5C-51
BRAKE CONTROL
REMOVAL AND INSTALLATION

BRAKE PEDAL ASSEMBLY

This illustration shows RHD model
LHD model is opposite.
310R300001

Removal Steps
1. Nut ; fulcrum pin
2. Pin ; fulcrum, pedal to bracket
3. Pedal arm
4. Return spring
5. Pedal pad

Installation steps
To install, follow the removal procedure in
reverse order.
Before installation, apply grease to the entire
circumference of the fulcrum pin (2).
Refer to "SERVICING" in this section for
adjustment procedure of brake pedal.

PARKING BRAKE SYSTEM 5D-1

SECTION 5D
BRAKES
PARKING BRAKE SYSTEM
CONTENTS

Service Precaution .......................................... 5D-1
Service Precaution ....................................... 5D-1
General Description ...................................... 5D-1
Parking Brake Lever ........................................ 5D-2
Parking Brake Lever Assembly and
Associated Parts (Bench Seat) .................. 5D-2
Removal ....................................................... 5D-3
Installation............................................................
5D-3
Front Parking Brake Cable....................................
5D-5
Front Parking Brake Cable and Associated
Parts (Bench Seat).........................................
5D-5
Removal...............................................................
5D-6
Installation............................................................
5D-6
Parking Brake Lever...............................................
5D-8
Parking Brake Lever Assembly and Associated
Parts (Buckle Seat)....................................... 5D-8
Removal ....................................................... 5D-8
Installation .................................................... 5D-8
Parking Brake Rear Cable ............................... 5D-9
Parking Brake Rear Cable and Associated
Parts ............................................................ 5D-9
Removal ....................................................... 5D-10
Installation .................................................... 5D-10
Inspection and Repair ................................... 5D-11
Parking Brake Adjustment ............................ 5D-11
Main Data and Specifications........................... 5D-12
Troubleshooting ............................................ 5D-13


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, REFE
R
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, o
r
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
Pulling up the parking brake lever by hand will set the
parking brake. By means of a ratchet type lock, the
lever can be held in that position until it is released. The
position of the lever is transmitted through cable/leve
r
systems to the rear wheels. These parts are designed
to obtain sufficient braking force even when parking on
slopes. When the parking brake is set, or when the
ignition SW is in the "ON" position, the brake warning
light illuminates. The rear wheel parking brake is a
leading-trailing brake (mechanical inside expansion
type) built in the rear drum brake. Parking brake
adjustment is made through the adjusting hole (bored
through back plate). Parking brake lever stroke should
be adjusted to 8

14 notches with 30kg (bench seat) o
r
6

8 notches with 30kg (bucket seat). Refer to “Parking
Brake Adjustment" in this section.

PARKING BRAKE SYSTEM 5D-3







This illustration shows RHD model
LHD model is opposite.
RTW35DLH000101

Legend

(1)
Nut

(2)
Bolt and Washer

(3)
Adjust Nut

(4)
Bolt


(5)
Front Parking Brake Cable

(6)
Clip

(7)
Switch

(8)
Bolt

(9)
Parking Lever Assembly


Removal
1. Remove instrument panel assembly & cross beam
in legend numbers order.

Refer to section 10.
2. Bolts (2)(8) are already removed in step 1.
3. Remove adjust nut (3).
4. Pull out clip (6) and take out front parking brake
cable (5) from parking lever assembly (9).
5. Remove bolts (4) and nut (1) and take out parking
lever assembly (9).
6. Remove switch (7).
Installation
1. Install switch (7).
Torque: 1.5 N




m (0.15 kg




m/13 lb in)
2. Set parking lever assembly (9).
3. Install bolts (4) and nut (1) and tighten them to the
specified torque.
Torque: 15 N





m (1.5 kg





m/11 lb ft)
4. Set front parking brake cable (5) in parking leve
r
assembly (9).
5. Drive clip (6) into the outer cable groove of front
parking brake cable (5) at the outside of parking
lever assembly (9).

5D-4 PARKING BRAKE SYSTEM

6. Drive adjust nut (3) on the front end of front
parking brake cable (5) so that front ends of rea
r
parking brake fit into the rear end (equalizer) of
front cable (5).
7. Install instrument panel assembly & cross beam.

Refer to section 10.
8. Install bolts (2) (8) and tighten them to the
specified torque.
Torque: 15 N




m (1.5 kg




m/11 lb ft)
9. Install all parts removed when removal steps.

Refer to section 10.
10. When a parking cable is replaced, pull parking
brake lever with a force equivalent to operating
force: 490N (50 kg/110 lb), 10 times fo
r
conditioning.
11. Adjust nut (3) so that lever (9) goes through 8

14
notches, when pulled with a operation force o
f
294N (30 kg/66 lb) and check brake for no drag.