2004 ISUZU TF SERIES lock

BRAKES 5C-39
DISASSEMBLY

CALIPER ASSEMBLY


Disassembly Steps
1. Bleeder with cap

2. Piston
3. Dust seal; piston
4. Ring seal
5. Body; caliper








Important Operations


2. Piston (with Ring Seal)
Insert a block of wood into the caliper and force out the piston
by blowing compressed air into the caliper at the flexible hose
attachment.
This procedure must be done prior to removal of dust seal.

CAUTION:
Do not place your fingers in front of the piston in an
attempt to catch or protect it when applying compressed
air.

5C-40 BRAKES
INSPECTION AND REPAIR

Make necessary correction or parts replacement if wear damage or any other abnormal conditions are found
through inspection.





Rotor


Caliper body

Cylinder bore


Piston


Support bracket


Lock bolt


Guide pin



Visual Check
Inspect the following parts for wear, bending, distortion,
cracking, corrosion, or other abnormal conditions.




Rotor

Thickness (t) mm(in)

Standard Replacement
thickness (Discard)
4

2 26.0 (1.024) 24.6 (0.969)
4

2 HIGH RIDE
4
4 27.0 (1.063) 25.6 (1.008)



Run out
Limit mm(in)
0.075 (0.0029)

Before inspection, adjust the wheel bearing correctly.
Using a dial gauge, measure the run out at the 10mm inside
position from rotor out side edge of disc pad contact surface.




Parallelism (Total circumferential thickness variation)
Limit mm(in)
0.023 (0.0009)

Contact surface must be within 0.023mm at the 10mm inside
position from rotor out side edge.
(Measurement; shall be measure more than 8 position at
circumferential direction.)

BRAKES 5C-43

3. Dust seal ; Piston
Install the dust seal on the pistons.
4. Piston
Apply clean brake fluid to the piston, the dust seal is certainly
put into the slot on the piston and attach the caliper.
When inserting the piston into the cylinder, use finger pressure
only. Do not use a mallet or other impact tools, since damage
to the cylinder wall or ring seal can result.
The movement of a caliper piston into a caliper bore should be
smooth and even. If a caliper piston is frozen or difficult to
bottom, the caliper requires overhaul or replacement.
RTW35CSH000701
When not entering with a finger, insert a discarded inner brake
pad (2) or block of wood in front of the pistons. Using 2 large
C-clamps (1) installed over the body of the caliper (3) and
against the brake pad or block of wood, slowly bottom the
pistons evenly into the bores.
Insert the dust seal ring into the dust seal.
CAUTION:
Piston made by plastic material.
Don’t must be hit on the piston by hammer etc. and don’t
grasp to face of piston by pliers.


5. Bleeder
Torque Nm(kgfm/Ibin)
9 – 16 (0.9 – 1.6 / 78 - 139)

6. Cap

5C-60 BRAKES
Inspection and Repair
Vacuum Hose (The built in check valve)
360R300002


1) Inspect the check valve (2), which is installed inside the
vacuum hose.
2) Blow air into the hose from the booster side as shown in
the illustration. The air should pass freely through the
hose.
3) Blow air into the hose from the engine side. The check
valve should close to block the passage of air.
The vacuum hose and built-in check valve must be
replaced as a set if either is found to be defective.

Important Operation-Installation
8. Vacuum Booster Assembly
7. Vacuum Booster Fixing Nut
6. Snap Pin
1) Perform vacuum booster and vacuum booster push rod
adjustment.
Note :
When replacing either the master cylinder or vacuum booster,
be sure to measure push rod, and adjust if required.

RTW35CSH000901

2) Measure the dimension (B) of master cylinder.


3) Apply negative pressure by means of vacuum pump so
that the pressure in the vacuum booster becomes
GASOLINE ENGINE: 66.7 kPa (500 mm Hg) or DIESEL
ENGINE 93.3 kPa (700 mm Hg).
Note :
Be sure to apply NEGATIVE pressure after installing a push
rod gauge on the vacuum booster.

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.

5D-10 PARKING BRAKE SYSTEM

Removal
1. Remove wheel and tire.
2. Remove brake drum.
3. Remove tension pin (1) and shoe clamp spring (2).
4. Remove return spring (3).
5. Remove shoe assemblly with parking brake leve
r
(4).
6. Remove shoe assembly with adjuster lever (5) and
spring (6).
7. Remove parking brake inner cable from parking
brake lever (4).
8. Use offset box wrench (12mm hex.) to compress
locking lugs on the cable, then remove parking
brake outer cable from back plate.
NOTE: Do not twist or bend the cable too much.
A damaged cable will cause poor operation or a cable
break down.





311RS012

Legend
(1) Offset Box Wrench (12mm hex)
9. Remove nut (8) to fix the cable (7) on the leaf
spring.
10. Take out parking brake rear cable (7) from the
back plate.
11. Remove bolt (9) and nut (10).
12. Disconnect T-end (11) from the equalizer of front
cable.

Installation
NOTE: Be sure to use the new shoe clamp spring (2)
and the new adjuster lever clip (14).
1. Apply grease (multipurpose type grease) to the
connecting portion of the rear cable (11) and
equalizer (13). (aroow mark).
2. Install parking brake outer cable in back plate and
inner cable in parking brake lever (4).
3. Install return spring (3).
4. Install shoe clamp spring (2) and tension pin (1)
5. Install shoe assembly with adjuster lever, shoe
assembly with parking brake lever (4) and spring
(6). ---- snap action
6. Install nut (8) and tighten it to the specified torque.
Torque: 7N




m (0.7 kg




m/61 lb in)
7. Connect T-end (11) with equalizer (13) through
outer cable retainer (12).
8. Install nut (10) and tighten it to the specifed
torque.
Torque: 15 N





m (1.5 kg





m/11 lb ft)
9. Install bolt (9) and tighten it to the specified
torque.
Torque: 7 N




m (0.7 kg




m/61 lb in)
10. Install brake drum.
11. Install wheel and tire.
12. Pull parking brake lever with a force equivalent to
poerating force: 490 N (50 kg/110 lb), 10 times fo
r
conditioning.
13. Adjust parking brake lever adjusting nut so that
parking brake lever goes through 8

14 (bench
seat) or 6

8 (bucket seat) notches, when pulled
with a operation force of 294N (30 kg/66 lb).
14. Check brake for no drag.

CAB 10-11


2. Check Arm Screw




3. Lower Hinge Bolt
Position a wood block under the door for protection and
support the door assembly with hands at removal or
installation.





Important Operations – Installation
3. Lower Hinge Bolt; Hinge to Door
Torque N

m (kgf

m/lb

ft)
34 (3.5/25)

2. Check Arm Screw; Check Arm to Body
Torque N
m (kgf
m/lb
ft)
24 (2.4/17)