2007 ISUZU KB P190 brakes

5C-42 BRAKES
REASSEMBLY
CALIPER ASSEMBLY


Reassembly Steps
▲ 1. Body; caliper
▲ 2. Ring seal
▲ 3. Dust seal; piston
▲ 4. Piston
▲ 5. Bleeder
▲ 6. Cap






Important Operations
1. Body; Caliper
2. Ring Seal
Apply clean brake fluid to the ring seal and cylinder wall, then
insert the ring seal into the cylinder.
Ensure that the piston ring seal are not twisted in the calipe
r
bore grooves.


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ISUZU KB P190 2007

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.


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ISUZU KB P190 2007

5C-44 BRAKES


5. Bleeder
Torque N ⋅m (kgf ⋅m/Ib ⋅ft)
9 – 16 (0.9 – 1.6 / 6.5 – 12)

6. Cap



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ISUZU KB P190 2007

BRAKES 5C-45
REAR DRUM BRAKE ASSEMBLY
DISASSEMBLY

First, disassemble the brake drum. Then disassemble the rear brake assembly.
Refer to the “REAR AXLE” section for the brake drum disassembly procedure.




RTW 75CMF001001

MAJOR COMPONENTS
Disassembly Steps

1. Spring; adjuster
2. Ring; Adjuster lever
3. Lever; adjuster
▲ 4. Spring; Shoe hold
5. Pin; Shoe hold
▲ 6. Spring; Shoe to shoe, lower
7. Adjuster assembly
8. Spring; shoe to shoe, upper
9. Shoe; leading

10. Shoe; trailing
11. Spring; lever return
12. Retainer
13. W asher; lever
14. Lever; parking
15. Bolt; wheel cylinder
16. W heel cylinder assembly
17. Cover
18. Back plate

MINOR COMPONENTS
Disassembly Steps
Wheel Cylinder Assembly

19. Piston assembly
20. Cup; piston
21. Boot; piston

22. Return spring
23. Cap; bleeder
24. Bleeder


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ISUZU KB P190 2007

5C-46 BRAKES



RUW 55CSH000401


Important Operations
4. Spring; shoe hold
Push the shoe hold spring toward the brake shoe and hold it
(1). Rotate the spring to remove it from the shoe hold pin (2).


6. Spring; shoe to shoe, lower
Slide the brake shoes and lower spring toward the ground.
Remove the lower spring.


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



• Brake drum
• Back plate
• Brake lining
• W heel cylinder body
• Piston
• Piston cup
• Return spring



Visual check
Inspect the following parts for wear scuffs, scratches,
corrosion, stains, deterioration, or other abnormal conditions.





Thickness of the Brake Lining
Thickness mm (in)
standard (T) Limit (t)
4× 2, 4 ×4 5.0 (0.197) 1.0 (0.039)



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ISUZU KB P190 2007

BRAKES 5C-47



Clean wheel Cylinder Parts
Always use clean brake fluid to clean wheel cylinder parts.
Note:
Do not use mineral based cleaning solvents such as
gasoline, kerosene, acetone, paint thinner, or carbon
tetrachloride.



Piston Cups
Inspect the piston cups for wear, distortion, fatigue or other
abnormal conditions.



Measuring the Brake Drum
mm (in)

Standard Limit
Inside diameter 254 (10.000) 255.5 (10.059)4×2
(Except HIGH
RIDE) Run out 0.08 (0.003) 0.15 (0.006)
Inside diameter 295 (11.614) 296.5 (11.673)4×2
(HIGH RIDE)4 ×4 Run out 0.08 (0.003) 0.15 (0.006)

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ISUZU KB P190 2007

5C-48 BRAKES
REASSEMBLY




RTW 75CMF000601

MINOR COMPONENTS
Reassembly Steps
Wheel cylinder Assembly

▲ 1. Piston assembly
2. Cup; piston
3. Return spring

4. Boot; piston
▲ 5. Bleeder
6. Cap; bleeder

MAJOR COMPONENTS
Reassembly Steps

7. Back plate
8. Cover
▲ 9. W heel cylinder assembly
▲ 10. Bolt; wheel cylinder
▲ 11. Shoe; leading
▲ 12. Lever; parking
▲ 13. W asher; lever
▲ 14. Retainer
15. Spring; lever return

▲
16. Shoe; trailing
▲ 17. Spring; shoe to shoe, upper
▲ 18. Adjuster assembly
19. Spring; shoe to shoe; lower
▲ 20. Lever; adjuster
▲ 21. Ring; Adjuster lever
▲ 22. Spring; shoe hold
▲ 23. Pin; shoe hold
24. Spring; adjuster



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ISUZU KB P190 2007

BRAKES 5C-49



Important Operations
Note:
• W ash the disassembled parts in clean brake fluid.
• Use compressed air to clean the ports.
• Protect the disassembled part surfaces from contamination
by dust and other foreign material.
• Before reassembly, check the part surfaces fo
r
contamination with dust or other foreign material.
• Be sure to replace the designated parts with new ones.

1. Piston Assembly
Install new piston cups on each piston so that the flared end of
the cups are turned to the inboard side of the pistons.
Attach the return spring and the boot to the piston.
Be sure to use new piston cup and boot.



RTW 55CSH000201

•
Apply brake fluid to the pistons and the inner face of the
boots.
• Note the direction of piston cup (1).
• Apply rubber grease to the boots (2) as shown in the
illustration.




5. Bleeder
Torque N ⋅m (kgf ⋅m/Ib ⋅in)
6 - 8 (0.6 – 0.8 / 52 - 69)




9. Wheel Cylinder Assembly
10. Bolt; Wheel cylinder
Torque N ⋅m (kgf ⋅m/Ib ⋅in)
14 - 18 (1.4 – 1.8 / 122 - 156)


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ISUZU KB P190 2007