2004 ISUZU TF SERIES brakes

BRAKES 5C-49
308R300008







11. Shoe ; leading

Be sure to use new spring; shoe hold.
12. Lever ; parking
13. Washer ; lever
14. Retainer
Install the lever, the washer and the retainer to the leading
brake shoe.



Apply grease to the sliding surfaces of the lever and
brake shoe.

Be sure to use new retainer and washer.
305R300009



















16. Shoe ; trailing


Be sure to use new spring; shoe hold.
17. Spring ; shoe to shoe, upper
18. Adjuster assembly
1. Apply grease to each of the parts shown in the
illustration before installing the brake shoe.

Lever; adjuster-shoe

Adjuster-shoe



2. Clean the adjuster bolt (5) and the adjuster rods (1) (4).
Apply grease to the threaded portion of the adjuster bolt.
3. Install the adjuster rod to the adjuster bolt.
4.
Apply grease to the adjuster asm ends (2) (3). Set the
spring ; upper to the adjuster asm, then install them to
the brake shoe.

305R300010











5. Before setting the brake shoes, apply grease to the back
plate portions (1) contacting the brake shoe edge as
shown in the illustration.
6.
Apply grease to the wheel cylinder parts contacting the
brake shoe (2).
7. Install the brake shoe.
Note :


Be careful not to damage the wheel cylinder dust cover.


Do not allow the wheel cylinder piston to fly free.

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)

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.

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-53
DISASSEMBLY

RTW35CMF000401

Disassembly Steps
1. Cap
2. Diaphragm
3. Bolt
4. Resever tank
5. Grommet




6. Snap ring

7. Stop pin

8. Primary piston

9. Secondary piston
10. Cylinder body


Note :
 Be sure to replace the designated with new ones.
 Wash the disassembled parts in clean brake fluid.
 Use compressed air to clean the ports.
 Do not allow dirt and dust to contaminate the disassembled
parts.

5C-54 BRAKES
Important Operations
When disassembling, inspecting or reassembling the master
cylinder assembly, take care not to bring the parts into contact
with mineral oil or dust. Wash the piston cups only with brake
fluid. Do not use gasoline or other mineral-base cleaning
solvents.



6. Ring ; Snap
Remove the snap ring from the cylinder body with pushing in
the primary and secondary pistons.
7. Stop Pin
Remove the stop pin from the cylinder body with pushing in the
primary and secondary pistons.


8. Piston Assembly ; Primary and Spring
9. Piston Assembly ; Secondary and Spring
Don’t remove the spring from the piston.

BRAKES 5C-55
INSPECTION AND REPAIR

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




Cylinder inside face


Piston


Piston cap


Piston cap spacer


Return port

Return spring


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



Return Port
Check the return port for obstructions and if necessary, clean
with a tag wire.
Blow away foreign matter with compressed air.



Primary Piston
After reassembly, push in the primary piston to see that returns
smoothly.
Repeat the test two or three times to see that brake fluid is
forced out from the front and rear outlets.

5C-56 BRAKES
REASSEMBLY



Reassembly Steps
1. Secondary piston
2. Primary piston
3. Cylinder body
4. Grommet
5. Reservoir tank


6. Stop pin
7. Bolt
8. Snap ring
9. Diaphragm
10. Cap




1. Secondary piston
Lubricate the piston cups on the secondary piston assemblies
with brake fluid.
Note :
Be sure to use a new piston.









2. Primary piston
Lubricate the piston cups on the primary piston assemblies
with brake fluid (1) and the rubber grease (2).
Note :
Be sure to use a new piston.