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 740 of 6020
BRAKES 5C-41
Thickness of Disc Pad
Thickness (t) mm (in)
Standard Limit
10.0 (0.394) 1.8 (0.071)
Replace the front disc pad whenever the pad wear indicato
r
makes a squeaking noise or when the pad is worn to within 1.8
mm of the shoe table.
All four brake pads should be replaced together.
302R300019
Seal and Boot
The dust seal, dust boot and ring seal should be replaced each
time the caliper is overhauled.
Discard these used rubber parts.
BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007
Page 741 of 6020
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.
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
Page 743 of 6020
5C-44 BRAKES
5. Bleeder
Torque N ⋅m (kgf ⋅m/Ib ⋅ft)
9 – 16 (0.9 – 1.6 / 6.5 – 12)
6. Cap
BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007
Page 744 of 6020
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
BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007