Isuzu N-Series. Service manual — part 233
HYDRAULIC BRAKES 5A-91
Master Cylinder Assembly (NKR / NPR / NQR / NPS)
Legend
1. Holder plate
13. Primary piston
2. Hose joint
14. Plug and O-ring
3. O-ring
15. Supporter
4. Primary piston assembly
16. Secondary piston assembly
5. Plug and O-ring
17. Primary cup
6. Secondary cup
18. Bushing
7. Bushing
19. O-ring
8. Primary cup
20. Secondary cup
9. Supporter
21. Screw
10. Screw
22. Spring retainer
11. Spring retainer
23. Secondary piston spring
12. Primary piston spring
24. Secondary piston
N5A0275E
5A-92 HYDRAULIC BRAKES
Disassembly
1. Holder Plate
2. Hose Joint
3. O-ring
4. Primary Piston Assembly
Draw out Piston by hand so that it may not be dam-
aged.
5. Plug and O-ring
Install master cylinder on a support plate (1), fix the
support in a vice, and loosen plug using a wrench
(2).
Support plate : 5-8840-2371-0
Wrench : 5-8840-2370-0
(Master cylinder inside diameter 31.7 mm, 30.1
mm)
Wrench : 5-8840-2369-0
(Master cylinder inside diameter 28.5 mm)
Wrench : 5-8840-2805-0
(Master cylinder inside diameter 34.9 mm)
6. Secondary Cup
7. Bushing
8. Primary Cup
9. Supporter
10. Screw
11. Spring Retainer
12. Primary Piston Spring
13. Primary Piston
14. Plug and O-ring
Install master cylinder on a support plate (1), fix the
support in a vice, and loosen plug using a wrench
(2).
Support plate : 5-8840-2371-0
Wrench : 5-8840-2370-0
(Master cylinder inside diameter 31.7 mm, 30.1
mm)
Wrench : 5-8840-2369-0
(Master cylinder inside diameter 28.5 mm)
Wrench : 5-8840-2805-0
(Master cylinder inside diameter 34.9 mm)
15. Supporter
16. Secondary Piston Assembly
17. Primary Cup
18. Bushing
19. O-ring
20. Secondary Cup
21. Screw
22. Spring Retainer
23. Secondary Piston Spring
24. Secondary Piston
Inspection and Repair
Make the necessary adjustments, repairs, and part re-
placements if excessive wear or damage is discovered
during inspection.
N5A0276E
N5A0277E
N5A0278E
HYDRAULIC BRAKES 5A-93
Cup and O-ring
1. Wash each part with brake oil and check for wear,
deterioration, and damage.
2. Replace the cups and O-rings.
Reassembly
1. Secondary Piston
2. Secondary Piston Spring
3. Spring Retainer
4. Screw
5. Secondary Cup
6. Bushing
Combine secondary cup and bushing with second-
ary piston as indicated as arrows, and push the as-
sembly in until bushing comes into contact with
cylinder body step.
7. O-ring
Install the O-ring to the bushing.
8. Primary Cup
9. Supporter
10. Plug and O-ring
Combine primary cup and supporter with plug as
indicated by arrows.
Then tighten plug to specified tightening torque.
Support plate : 5-8840-2371-0
Wrench : 5-8840-2370-0
(Master cylinder inside diameter 31.7 mm, 30.1
mm)
Wrench : 5-8840-2369-0
(Master cylinder inside diameter 28.5 mm)
Wrench : 5-8840-2805-0
(Master cylinder inside diameter 34.9 mm)
Notice:
If plug tightened to specified torque is found floating
from cylinder body, plug should be disassembled again
and check for abnormal parts fitting. Then reassemble.
N5A0281E
Plug Torque
N
⋅m (kg⋅m/lb⋅ft)
Master Cylinder
Inside diameter
(mm)
28.5
40 (4.1/30)
30.1
44 (4.5/33)
31.7
34.9
49 (5.0/37)
N5A0282E
5A-94 HYDRAULIC BRAKES
11. Primary Piston
12. Primary Piston Spring
13. Spring Retainer
14. Screw
15. Supporter
16. Primary Cup
17. Bushing
1) Combined the parts of primary piston as indi-
cated by arrows.
Then push the assembly in until bushing comes
into contact with the step in cylinder body.
2) Draw out primary piston alone taking care not
to be let bushing get out of the step.
18. Secondary Cup
19. Plug and O-ring
Combine secondary cup with plug as indicated by
arrow, and tighten to specified tightening torque.
Support plate : 5-8840-2371-0
Wrench : 5-8840-2370-0
(Master cylinder inside diameter 31.7 mm, 30.1
mm)
Wrench : 5-8840-2369-0
(Master cylinder inside diameter 28.5 mm)
Wrench : 5-8840-2805-0
(Master cylinder inside diameter 34.9 mm)
Notice:
If plug tightened to specified torque is found floating
from cylinder body, plug should be disassembled again
and check for abnormal parts fitting. Then reassemble.
20. O-ring
21. Hose Joint
22. Holder Plate
N5A0283E
N5A0284E
Plug Torque
N
⋅m (kg⋅m/lb⋅ft)
Master Cylinder
Inside diameter
(mm)
28.5
40 (4.1/30)
30.1
44 (4.5/33)
31.7
34.9
49 (5.0/37)
N5A0285E
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