2004 ISUZU TF SERIES lock

BRAKES 5C-29

ADJUSTMENT PROCEDURE OF SERVICE AND PARKING BRAKE




Stem type
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 lever to its fully released position.

311R300007





























































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 i
t
until the clicking sound can no longer be heard.

If the difference between the brake drum inside diameter o
f
the brake shoes is adjusted to be 0.5 mm, the number o
f
times for depressing the brake pedal can be reduced.
4. Remove the drum.

Measure the brake drum inside diameter and diameter o
f
the brake shoes.
Shoe Clearance mm(in)
0.25 - 0.40 (0.0098 - 0.0157)
If incorrect, check the brake auto-adjusting system.
5. Turn the adjuster nut so that the parking brake lever travels
8 to 14 notches when pulled up with a force 30 kg (66 lbs.).
6. Make sure there is not brake dragging.



Floor mount type
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 lever 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 i
t
until the clicking sound can no longer be heard.

If the difference between the brake drum inside diameter o
f
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 o
f
the brake shoes.

BRAKES 5C-31

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.

RTW35CSH000601


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)
M/T 174-186 (6.85-7.32)
RHD
LHD
A/T 176-188 (6.93-7.40) 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.



Lock Nut Torque N

m(kgf

m/lb
 
ft)
12 - 18 (1.2 – 1.8 / 9 - 13)

d) Install the stop lamp switch.

Note:
Pedal height (L
2) must be 80 mm (3.14 in.) or more when
applying about 50 kg (110.25 lbs.) of stepping force.

331R300005


How to connect the CLEVICE of BOOSTER ROD with PEDAL
ARM. and how to adjust the PEDAL SW.
After connecting the CLEVIS of BOOSTER ROD with PEDAL
ARM, adjust the PEDAL SW mounted (PDA) to PEDAL
BRACKET by the procedure explained still more bellow.
1. Set the hole of the CLEVIS of BOOSTER&M/CYL ROD
with the hole of the PEDAL ARM.
2. Enter the PIN; PUSH ROD to PEDAL to these holes
from left side of the PEDAL.
3. Enter and fix the PIN; SANP PIN FIX to the DITCH o
f
the PIN; PUSH ROD to PEDAL from right side of the
PEDAL.
4. Release the LOCK by turning the SWITCH counter-
clock-wise.

5C-32 BRAKES


5. After doing so, pull PEDAL ARM to yourself a little so
that PEDAL ARM is not pushed in.
6. Making PEDAL ARM not movable with one hand, push
in the whole SWITCH with the other hand until the
PLUNGER of SWTCH is pushed in and SWITCH itself
hits the RUBBER of PEDAL ARM.
In the condition, turn SWITCH clock-wise until “click”
sound is made and lock it.
By doing this the SWITCH is adjusted at 0.70.5mm
clearance.

BRAKES 5C-33
FRONT BRAKE ASSEMBLY
REMOVAL AND INSTALLATION



Removal Steps


1. Brake flexible hose


2. Lock bolt

3. Pad assembly
4. Clip; pad
5. Caliper assembly

6. Support bracket


7. Front hub and disc assembly

Installation Steps



7. Front hub and disc assembly


6. Support bracket
5. Caliper assembly


4. Clip; pad
3. Pad assembly with shim

2. Lock bolt


1. Brake flexible hose

5C-34 BRAKES



Important Operations - Removal
1. Brake Flexible hose
Remove the bolt and gasket and disconnect the brake flexible
hose from the caliper.
After disconnecting the flexible hose, cap or tape the openings
to prevent entry of foreign material.



2. Lock Bolt
Remove the lock bolt from the caliper.



3. Pad Assembly with Shim
Rotate the caliper upward.



Mark the lining locations if they are to be reinstalled.

5C-36 BRAKES


6. Support Bracket
Torque N
m(kgf
m/lb
ft)
196 - 235 (20.0 – 24.0 / 145 - 174)
Set up the clip and pad before installation of the support
racket.
4. Clip ; Pad
Install new parts if necessary.


2. Lock Bolt
Torque N

m(kgf

m/lb

ft)
32 - 40 (3.3 – 4.1 / 24 - 30)






1. Brake Flexible Hose
Attach the bolt and new gasket
Torque N
m(kgf
m/lb
ft)
29 -39 (3.0 - 4.0 / 22 - 29)

After installation, bleeding and replenishing procedure must be
performed.
Wipe the circumference of the hose clean.
Note:






Always use new gaskets.

Be sure to put the hooked edge of the flexible hose end into
the anti-rotation cavity.

BRAKES 5C-37

REMOVAL AND INSTALLATION OF DISC PAD




Removal Steps
1. Lock Bolt
Remove the lock bolt from the caliper.
Note:
Don't remove the brake hose from caliper when replacing
pads.



2. Rotate the Caliper Upward
Remove the caliper from the support bracket and the caliper to
the upper link or the frame.
Note:
While caliper is removed from support bracket, never step
on the brake pedal or the piston will protrude rapidly.




3. Pad Assembly with Shim
Remove the pad assembly with the shim.
Mark the pad locations if they are to be reinstalled.



4. Clip ; Pad
Discard the used clip and install a new one.



Installation Steps
1. Clip ; Pad
2. Pad Assembly with Shim
After attaching the pad assembly with the shim to the support
bracket, position the wear indicator to the lower side of the
inner pad and position the wear indicator to the upper side of
the outer pad.

5C-38 BRAKES





3. Caliper Assembly
Lower the caliper into its original position.
Do not damage the flexible hose by twisting or pulling it.


4. Lock Bolt
Attach the lock bolt to the caliper.
Torque N
m(kgf
m/lb
ft)
32 - 40 (3.3 – 4.1 / 24 - 30)