Isuzu Amigo / Axiom / Trooper / Rodeo / VehiCross. Service manual — part 699
5C–40 POWER ASSISTED BRAKE SYSTEM
Front Disc Brake Caliper
Front Disc Brake Caliper Disassembled View
302RW015
Legend
(1) Guide Bolt
(2) Lock Bolt
(3) Bleeder with Cap
(4) Caliper Body
(5) Dust Boot: Guide Bolt and Lock Bolt
(6) Piston Seal
(7) Piston
(8) Dust Boot: Piston
(9) Dust Boot Ring
Disassembly
1. Remove guide bolt.
2. Remove lock bolt.
3. Remove dust boot: guide bolt and lock bolt.
4. Remove dust boot ring, using a small screwdriver,
remove the dust boot ring.
302RS016
5C–41
POWER ASSISTED BRAKE SYSTEM
5. 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 boot.
WARNING: DO NOT PLACE YOUR FINGERS IN
FRONT OF THE PISTON IN AN ATTEMPT TO CATCH
OR PROTECT IT WHEN APPLYING COMPRESSED
AIR. THIS COULD RESULT IN PERSONAL INJURY.
CAUTION: Use just enough air to ease the piston
out of the bore. If the piston is blown out, it may be
damaged.
302RS017
6. Remove dust boot: piston.
7. Remove piston seal.
8. Remove bleeder with cap.
9. Remove caliper body.
Inspection and Repair
Make necessary parts replacement, if wear, damage,
corrosion or any other abnormal conditions are found
through inspection.
Check the following parts:
D
Rotor
D
Cylinder body
D
Cylinder bore
D
Piston
D
Guide bolt, lock bolt
D
Support bracket
NOTE: The piston seal, boot ring and dust boot are to be
replaced each time the caliper is overhauled. Discard
these used rubber parts and replace them with new ones.
Reassembly
1. Install caliper body.
2. Install bleeder with cap and tighten the cap to the
specified torque.
Torque: 8 N·m (69 lb in)
3. Install piston seal and apply special rubber grease to
the piston seal and cylinder wall, then insert the piston
seal into the cylinder. The special rubber grease is
included in the repair kit.
302RS018
4. Install piston.
5. Install piston dust boot; when inserting the piston into
the cylinder, use finger pressure only and do not use a
mallet or other impact tool, since damage to the
cylinder wall or piston seal can result.
302RS019
5C–42 POWER ASSISTED BRAKE SYSTEM
6. Install dust boot ring and apply special grease
(approximately 1 g) to the piston and attach the dust
boot to the piston and caliper. Insert the dust boot ring
into the dust boot.
302RS020
7. Install guide bolt and lock bolt dust boot.
8. Install lock bolt and guide bolt and tighten the bolt to
the specified torque.
Torque: 74 N·m (54 lb ft)
9. Install the dust boot on the support bracket after
applying special grease (approximately 1 g) onto the
dust boot inner surface. Apply special grease onto the
lock bolt and guide bolt setting hole of the support
bracket.
302RS021
5C–43
POWER ASSISTED BRAKE SYSTEM
Main Data and Specifications
General Specifications
Type
Floating, pin slide
Pad dimension
55 cm
@
(8.52 in
@
)
Adjusting method
Self–adjusting
Piston diameter
60.33 mm (2.38 in)
Disc type
Ventilated
Disc thickness
26 mm (1.02 in)
Disc effective diameter
222 mm (8.74 in)
Torque Specifications
E05RW004
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