Page 732 of 6020
BRAKES 5C-33
FRONT DISC BRAKE ASSEMBLY
REMOVAL AND INSTALLATION
RTW 55CMF000501
Removal Steps
1. Brake flexible hose
2. Lock bolt
3. Caliper assembly
4. Pad assembly with shim
5. Clip; pad
6. Slide pin
7. Boot
8. Support bracket
9. Front hub and disc assembly
Installation Steps
9. Front hub and disc assembly
8. Support bracket
7. Boot
6. Slide pin
5. Clip; pad
4. Pad assembly with shim
3. Caliper assembly
2. Lock bolt
1. Brake flexible hose
BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007
Page 733 of 6020
5C-34 BRAKES
RUW 55CSH000101
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.
RUW 55CSH001501
2. Lock Bolt
Remove the lock bolt from the caliper.
4. Pad Assembly with Shim
Rotate the caliper upward.
RUW 55CSH001601
Mark the lining locations if they are to be reinstalled.
RUW 55CSH000101
8. Support Bracket
Take care not to damage the brake flexible hose when
removing the support bracket.
BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007
Page 734 of 6020
BRAKES 5C-35
9. Front Hub and Disc Assembly
For the removal procedure, refer to Section 4C “FRONT
W HEEL DRIVE”.
Important Operations - Installation
9. Front Hub and Disc Assembly
For the installation procedure, refer to the front hub and disc
reassembly procedure in Section 4C “FRONT W HEEL
DRIVE”.
RUW 55CSH000101
8. Support Bracket
Torque N ⋅m (kgf ⋅m/lb ⋅ft)
206 - 245 (21.0 – 25.0 / 152 - 181)
Set up the clip and pad before installation of the support
bracket.
7. Boot
6. Slide Pin • Be sure to install the boots to the slide pin and the
support bracket securely.
•
Apply rubber grease to the sliding surface of the slide
pin before installation of the slide pin. (Don’t use mineral
type grease.)
1) Assemble a slide pin boot to a slide pin.
2) Use 0.6g to apply grease to the slide pin entirely as shown bellow.
3) Insert the slide pin to the housing and make sure the boot is also inserted to the housing tightly.
5. Clip; Pad
Install new parts if necessary.
RUW 55CSH000201
2. Lock Bolt
Torque N ⋅m (kgf ⋅m/lb ⋅ft)
32 - 40 (3.3 – 4.1 / 24 - 30)
BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007
Page 736 of 6020
BRAKES 5C-37
REMOVAL AND INSTALLATION OF DISC PAD
RUW 55CSH001501
Removal Steps
1. Lock Bolt
Remove the lock bolt from the caliper.
Note:
Don’t remove the brake hose from the caliper when
replacing pads.
2. Rotate the Caliper Upward
Remove the caliper from the support bracket and move the
caliper to the upper link or the frame.
Note:
While caliper is removed from the support bracket, neve
r
step on the brake pedal or the piston will protrude rapidly.
RUW 55CSH001601
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.
BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007
Page 737 of 6020
5C-38 BRAKES
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 o
f
the outer pad.
RUW 55CSH001701
3. Caliper Assembly
Lower the caliper into its original position.
Do not damage the flexible hose by twisting or pulling it.
RUW 55CSH000201
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)
BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007
Page 738 of 6020
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 the 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.
BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007
Page 739 of 6020
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)
StandardReplacement thickness
(Discard)
4×2
(Except HIGH RIDE) 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 10 mm inside
position from the rotor out-side edge of the disc pad contact
surface.
•
Parallelism (Total circumferential thickness variation)
Limit mm (in)
0.023 (0.0009)
Contact surface must be within 0.023 mm at the 10 mm inside
position from rotor-out side edge.
(Measurement; should be measured at more than 8 positions
in circumferential direction.)
BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007
Page 742 of 6020
BRAKES 5C-43
3. Dust seal; Piston
• Apply grease to piston groove and dust seal boot.
1) Make sure a piston and its groove area are free from dust.
2) Use 0.5g to apply grease to groove area thoroughly using a brush or finger.
Make sure color of groove changes as shown bello
w
after apply grease.
3) After assembling a dust seal boot to the piston, apply
1.5g to contact area of the piston and the dust seal boot
as shown in the picture bellow.
4. Piston
Apply clean brake fluid to the piston, and attach the caliper.
W hen inserting the piston into the cylinder, use finger pressure
only. Do not use a mallet or other impact tool, 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
move to the bottom, the caliper requires overhaul o
r
replacement.
RTW 35CSH000701
W hen 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 move the
pistons evenly into the bores.
Insert the dust seal ring into the dust seal.
CAUTION:
Pistons made of plastic material.
Do not hit the piston with a hammer etc. and don’t grasp
the face of the piston with pliers.
BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007
