2004 ISUZU TF SERIES Workshop Manual

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Page 449 of 4264

ISUZU TF SERIES 2004 Workshop Manual BRAKES 5C-23

RTW35CSH001301

4) Failure on front master cylinder.
In case of failure on front master cylinder the pressure on
the inlet port (C) drop to zero. The pressure from inlet por
t

Page 450 of 4264

ISUZU TF SERIES 2004 Workshop Manual 5C-24 BRAKES

RTW35CSH000201
3) Rear wheel cylinder fluid pressure measurement
Step on the brake pedal until the fluid pressure of the
front wheel cylinder gets to 9.8Mpa (100kg/cm
2), and
c

Page 451 of 4264

ISUZU TF SERIES 2004 Workshop Manual BRAKES 5C-25

Filling Master Cylinder Reservoir
CAUTION :
Use only specified brake fluid. Do not use any fluid which
contains a petroleum base. Do not use a container which
has been used f

BRAKES 5C-25

Filling Master Cylinder Reservoir
CAUTION :
Use only specified brake fluid. Do not use any fluid which
contains a petroleum base. Do not use a container which
has been used for petroleum based fluids or a container
which is wet with water. Petroleum based fluid will cause
swelling and distortion of rubber parts in the hydraulic
brake system. Water mixed with brake fluid lowers the
fluid boiling point. Keep all fluid containers capped to
prevent contamination.
Always fill the master cylinder reservoir when the engine
is cold.
Never allow the brake fluid to come in contact with the
painted surfaces.
The master cylinder reservoir must be kept properly filled
to ensure adequate reserve and to prevent air and
moisture from entering the hydraulic system. However,
because of expansion due to heat absorbed from the
brakes and the engine, the reservoir must not be
overfilled. Thoroughly clean reservoir cap before removal
to avoid getting dirt into reservoir. Add fluid as required to
bring level to the “MAX” mark on the reservoir tank. Use
“DOT 3” Hydraulic Brake Fluid.

Leakage of Brake Fluid
With engine idling, set shift lever in the neutral position and
continue to depress brake pedal at a constant pedal
application force.
Should the pedal stroke become deeper gradually, leakage
from the hydraulic pressure system is possible.
Make sure by visual check that there is no leak.

BLEEDING OF THE BRAKE HYDRAULIC
CIRCUIT
If air enters the bake lines, it will cause poor brake action.
Therefore, bleeding should be performed if the brakes have
been used with the level of brake fluid in the reservoir
excessively low or if brake pipes have been disconnected in
the course of brake servicing.
Bleeding operation calls for co-operative action of 2 persons.

Set the parking brake firmly while bleeding.

Perform bleeding operation with ENGINE RUNNING, to
prevent damage to push rod seal.

Make sure exhaust is suitably ventilated.

Bleed the hydraulic system with the fluid reservoir filled to
the specified level.

Bleed the system starting with the rear wheel cylinde
r
farthest from the master cylinder.

Page 452 of 4264

ISUZU TF SERIES 2004 Workshop Manual 5C-26 BRAKES

A bleeding operation is necessary to remove air from the
hydraulic brake system whenever air is introduced into the
hydraulic system. It may be necessary to bleed the hydraulic
s

5C-26 BRAKES

A bleeding operation is necessary to remove air from the
hydraulic brake system whenever air is introduced into the
hydraulic system. It may be necessary to bleed the hydraulic
system at all four brakes if air has been introduced through a
low fluid level or by disconnecting brake pipes at the master
cylinder. If a brake pipe is disconnected at one wheel, only that
wheel cylinder/caliper needs to be bled. If the pipes are
disconnected at any fitting located between the master cylinder
and brakes, then the brake system served by the disconnected
pipe must be bled.

1. Set the parking brake completely, then start the engine.
NOTE :
The vacuum booster will be damaged if the bleeding operation
is performed with the engine off.
2. Remove the master cylinder reservoir cap.

3. Fill the master cylinder reservoir with brake fluid. Keep the
reservoir at least half full during the air bleeding operation
4. Always use new brake fluid for replenishment.
5. In replenishing rake fluid, take care that air bubbles do no
t
enter the brake fluid.

When the master cylinder is replaced or overhauled, firs
t
bleed the air from the master cylinder, then from each
wheel cylinder and caliper following the procedures
described below.

Bleeding the Master Cylinder
6. Disconnect the rear wheel brake pipe (1) from the master
cylinder.
Check the fluid level and replenish as necessary. If
replenished, leave the system for at least one minute.
7. Depress the brake pedal slowly once and hold it depressed.
8. Completely seal the delivery port of the master cylinder with
your finger, where the pipe was disconnected then release
the brake pedal slowly.
9. Release your finger from the delivery port when the brake
pedal returns completely.
10. Repeat steps 7 through 9 until the brake fluid comes out o
f
the delivery port during step 7.
NOTE : Do not allow the fluid level in the reservoir to go below
the half-way mark.
11. Reconnect the brake pipe (1) to the master cylinder and
tighten the pipe.
12. Depress the brake pedal slowly once and hold it depressed.
13. Loosen the rear wheel brake pipe (1) at the master cylinder.
14. Retighten the brake pipe, then release the brake pedal
slowly.

Page 453 of 4264

ISUZU TF SERIES 2004 Workshop Manual BRAKES 5C-27

15. Repeat steps 12 through 14 until no air comes out of the
port when the brake pipe is loosened
NOTE : Be very careful not to allow the brake fluid to come in
contact with pain

Page 454 of 4264

ISUZU TF SERIES 2004 Workshop Manual 5C-28 BRAKES

27. After the bleeding operation is completed on the each
individual wheel, check the level of the brake fluid in the
reservoir and replenish up to the “MAX" level as necessary.
2

Page 455 of 4264

ISUZU TF SERIES 2004 Workshop Manual 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

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.

Page 456 of 4264

ISUZU TF SERIES 2004 Workshop Manual 5C-30 BRAKES

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
6 to

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