Isuzu N-Series. Service manual — part 228
HYDRAULIC BRAKES 5A-71
UNIT REPAIR
Wheel Cylinder Assembly (without Auto-adjuster)
Legend
A. 2L type
3. Piston and cup assembly
B. D2L type
4. Boot
1. Adjusting screw
5. Wheel cylinder body
2. Lock plate
6. Bleeder screw
N5A0231E
5A-72 HYDRAULIC BRAKES
Disassembly
2L Type
D2L Type
1. Adjusting Screw
2. Lock Plate
3. Piston and cup Assembly
4. Boot
5. Wheel Cylinder Body
6. Bleeder Screw
Store all of the removed parts in a clean part tray.
Inspection and Repair
Make the necessary adjustments, repairs, and part re-
placements if excessive wear or damage is discovered
during inspection.
Wheel Cylinder Assembly
Wheel Cylinder and Piston Clearance
1. Use a micrometer to measure the piston diameter.
2. Use an inside dial indicator to measure the cylinder
bore.
3. Calculate the clearance between the wheel cylin-
der and the piston.
If the clearance exceeds the specified limit, the pis-
ton and/or wheel cylinder body must be replaced.
When the wheel cylinder disassembled, the repair
kit (piston cup and boot) must be replaced.
Reassembly
1. Bleeder Screw
2. Wheel Cylinder Body
1) Apply a coat of rubber grease to the cylinder
body bore (1) and the grooves for the boots (2).
2) Fit the boot edge securely into the mating
groove of the cylinder body.
N5A0232E
N5A0233E
Wheel Cylinder and Piston Clearance
mm (in)
Wheel Cylinder size
Limit
22.22 (0.875)
25.40 (1.000)
28.57 (1.125)
30.16 (1.188)
33.33 (1.312)
34.93 (1.375)
0.15 (0.006)
N5A0234E
HYDRAULIC BRAKES 5A-73
3. Boot
4. Piston Assembly
1) Apply a coat of rubber grease to the piston cups
and the pistons.
Be sure to lubricate the entire cylinder body
bore with the rubber grease.
2) Install the piston assembly to the cylinder.
Notice:
After installation of the piston assembly into the cylinder
body bore, fit the boot edge securely into the mating
groove of the piston.
Make sure that the two boot edges firmly sealed into the
grooves.
Be careful not to damage the piston cups and the boots.
2L Type
D2L Type
1. Lock Plate
2. Adjusting Screw
Apply a coat of molybdenum disulfide grease to the
adjusting screw slit and threads.
Legend
1. Cylinder body bore
2. Groove
3. Boot
N5A0236E
N5A0237E
Legend
1. Piston cup
2. Edge
3. Boot
Legend
1. Piston cup
2. Piston
3. Boot
4. Grease
N5A0238E
5A-74 HYDRAULIC BRAKES
Wheel Cylinder Assembly (with Auto-adjuster)
Legend
A. Drum inside diameter 260 mm
6. Adjuster gear and nut assembly
1. Overtravel spring
7. Washer
2. Return spring
8. Piston and cup assembly
3. Fitting
9. Boot
4. Adjuster lever
10. Wheel cylinder body
5. Adjusting screw
11. Bleeder screw
N5A0240E
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