2004 ISUZU TF SERIES torque

5C-48 BRAKES



Important Operations
Note :


Wash the disassembled parts in clean brake fluid.


Use compressed air to clean the ports.


Protect the disassembled part surfaces from dust and othe
r
foreign material contamination.


Before reassembly, check the part surfaces for dust and
other foreign material contamination.


Be sure to replace the designated parts with new ones.

4. Piston Assembly
Install new piston cups on each piston so that the flared end of
the cups are turned to the inboard side of the pistons.
Attach the return spring and the boot to the piston.
Be sure to use new piston cup and boot.




Apply brake fluid to the piston and the inner face of the
boots.


Note the direction of piston cup.



5. Bleeder ; Wheel Cylinder
Torque Nm(kgfm/Ibin)
6 - 8 (0.6 – 0.8 / 52 - 69)



9. Wheel Cylinder Assembly
10. Bolt ; Wheel cylinder
Torque N
m(kgf
m/Ib
ft)
7 - 11 (0.7 – 1.1 / 61 - 95)

5C-50 BRAKES












20. Lever ; adjuster
21. Ring ; Adjuster lever


Apply grease to the lever ; adjuster sliding surface.
Install the lever ; adjuster and the ring to the shoe ;
trailing.


Be sure to use new ring.

P1010008B


23. Pin ; shoe hold
24. Spring ; shoe hold

Install the brake drum.


Install the rear wheel.


If the wheel cylinder has been removed, the brake
system must be bled.


Pump the brake pedal 10 times. Check that there is little
or no stroke length variation as the pedal is pumped.


Adjust the lining clearance.




Brake Line
Torque N
m(kgf
m/Ib
ft)
13 - 19 (1.3 - 1.9 / 9 - 14)

5C-52 BRAKES
MASTER CYLINDER
REMOVAL AND INSTALLATION

MASTER CYLINDER ASSEMBLY



This illustration is based on RHD model.
330R300008

Removal Steps

1. Brake line
2. Nut ; master cylinder to vacuum booster
3. Master cylinder assembly

Installation Steps
3. Master cylinder assembly

2. Nut ; master cylinder to vacuum booster

1. Brake line




Important Operation - Removal
1. Brake Line
Be very careful not to spill brake fluid on the painted surface.
Damage to the painted surface will result.








Important Operation - Installation
2. Nut ; Master Cylinder to Vacuum Booster
Torque N
m (kgf
m/lb
ft)
12 – 18 (1.2 – 1.8 / 9 – 13)

1. Brake Line
Torque N

m (kgf

m/lb

ft)
13 – 19 (1.3 – 1.9 / 9 – 14)

BRAKES 5C-57


3. Cylinder body
Install the secondary piston and the primary piston to the
cylinder body.
Note :
The secondary piston long hole and the cylinder body stop pin
hole must be aligned at installation.



4. Grommet
5. Reservoir tank
6. Stop pin
7. Bolt
1. Install the grommets to the reservoir tank.
Note :
Be sure to use are new grommets.

330R300018












































































2. Press down on the primary piston and install the stop pin
to the cylinder body (the piston long hole must be
aligned with the cylinder body installation hole).
3. Install the reservoir tank to the cylinder body.
4. Tighten the bolts to the specified torque.
Torque N

m (kgf

m/lb

in)
2 - 3 (0.2 - 0.3 / 17 - 26)



8. Snap pin
Press down on the primary piston and install the snap ring to
the cylinder body groove.
Note :
Be sure to use new snap ring.
9. Diaphragm
10. Cap

BRAKES 5C-61


















4) Measure dimension (A)

RTW35CSH000801







5) Calculate the gap (B-A) when assembling the master
cylinder and vacuum booster.

GAP mm (in
)
0 
0.4 (0 
0.0157)



6) If dimension (A) is out of the standard range, adjust the
push rod.

Loosen the push rod lock nut (1) on the vacuum
booster.

Set the clevis (2).

Use the adjuster (3) to adjust the length of the
protruding portion of the push rod.

Vacuum (negative) pressure should be GASOLINE
ENGINE: 66.7 kPa (500mm Hg) or DIESEL
ENGINE: 93.3 kPa (700mm Hg) after adjustment.

Tighten the push rod lock nut to the specified torque.







Torque N

m(kgf

m/lb

ft)
18 – 25 (1.8 – 2.5 / 13 – 18)

7) Install the vacuum booster assembly to the dash panel
and pedal mounting bracket.
Torque N

m(kgf

m/lb

ft)
18 – 24 (1.8 – 2.4 / 13 – 17)

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.