Isuzu N-Series. Service manual — part 196
SERVICE INFORMATION 00-1
BRAKES
SECTION 00
SERVICE INFORMATION
Contents
TROUBLESHOOTING . . . . . . . . . . .. 00-2
Service Brakes . . . . . . . . . . . . 00-39
Parking Brake . . . . . . . . . . . . .. 00-45
FIXING TORQUE. . . . . . . . . . . . 00-47
SPECIAL TOOLS. . . . . . . . . . . . 00-57
00-2 SERVICE INFORMATION
TROUBLESHOOTING
Brake System
PROBLEM
POSSIBLE CAUSE
CORRECTION
No Brakes
1. Restricted tubing or hose.
1. Replace defective parts.
2. Brakes out of adjustment.
2. Adjust.
3. No fluid.
3. Fill the reservoir with brake fluid.
Insufficient Brakes
1. Pedal improperly adjusted.
1. Adjust.
2. Worn linings/pads or drum/discs.
2. Replace as necessary.
3. Plugged, crimped, restricted lines or
hoses.
3. Repair or replace.
Slow Brake Application
1. Pedal binding.
1. Lubricate pivot pin, clean-check for for-
eign objects.
2. Wheel cylinder piston sticking.
2. Repair the wheel cylinder.
3. Restriction in the lines.
3. Remove the restriction or replace the
line.
4. Worn linings/pads or drums/discs.
4. Replace as necessary.
Uneven Braking
(Front or Rear Brakes
not Working)
1. Damaged hydraulic lines.
1. Repair or replace.
2. No brake fluid at the master cylinder.
2. Check for plugged, kinked or damaged
hose to the reservoir.
3. Safety valve not opened.
3. Correct.
Wet Weather:
Brakes Grab or won't
Hold
1. Linings too sensitive to water.
1. Replace in axle sets.
2. Dirty brakes.
2. Clean out.
3. Bent mounting plate - opening.
3. Replace.
4. Scored drums/discs.
4. Machine in pairs. Replace if necessary.
Brakes Squeak
1. Mounting plate bent or shoes twisted.
1. Replace damaged parts.
2. Metallic particles or dust imbedded in
the lining.
2. Replace the linings/pads in axle sets.
3. Lining rivets loose or lining not held
tightly against the shoe at the ends.
3. Replace the rivets and/or tighten the lin-
ing by riveting.
4. Drums distorted tampered, or not
Square.
4. Machine or replace drums/discs.
5. Incorrect lining/pad.
5. Replace the linings/pads in axle sets.
6. Mixed size linings.
6. Use all standard or oversize linings in a
brake.
7. Weak or broken return spring.
7. Replace the return spring.
8. Loose wheel bearings.
8. Tighten to the proper setting.
9. Loose mounting plate, drum, wheel cyl-
inder.
9. Tighten.
10. Linings/pads located wrong on the
shoes.
10. Install the linings correctly.
11. Linings/pads worn out.
11. Reline the brakes.
12. Lining glazed.
12. Replace.
13. Cracked or threaded drums/discs.
13. Replace in axle pairs.
SERVICE INFORMATION 00-3
Brakes Chatter
1. Incorrect lining/pad to drum/disc clear-
ance.
1. Adjust to specification.
2. Loose mounting plate.
2. Tighten securely.
3. Grease, fluid, road dust on the lining
pad.
3. Clean or reline.
4. Weak or broken return spring.
4. Replace the return spring.
5. Loose wheel bearings.
5. Readjust.
6. Drums out-of-round.
6. Machine the drums in axle sets.
7. Discs warped.
7. Machine the discs in axle sets.
8. Cocked or distorted shoes.
8. Straighten or replace.
9. Distorted, tapered, or barrel- shaped
drums.
9. Machine drums in pairs. Replace if nec-
essary.
10. Incorrect lining/pad material.
10. Reline with correct linings/pads.
11. Linings/pads worn out.
11. Reline the brake.
12. Lining loose on the shoes.
12. Rerivet the linings to the shoes.
Replace if necessary. Check for dam-
aged or distorted shoes.
13. Foreign material imbedded in the lin-
ings/pads.
13. Replace the linings/pads in axle sets.
14. Cracked or threaded drums/discs.
14. Replace in axle pairs.
Shoe Click
1. Return spring weak.
1. Replace the spring.
2. Shoe bent.
2. Straighten or replace.
Noise and Chatter
Squealing, clicking, or
scraping sound upon
brake application
1. Bent, damaged or incorrect shoes.
1. Replace with the correct shoes and lin-
ing. Always replace in axle sets.
2. Worn out lining/pad.
2. Replace the shoes and lining/pad in
axle sets.
3. Foreign material embedded in the lin-
ing/pad.
3. Replace the shoes and lining/pad in
axle sets.
4. Broken shoe return spring.
4. Replace the return spring.
5. Cracked or threaded drums/discs (lathe
marks).
5. Replace the drums/discs in axle sets.
Pulls to One Side
1. Grease or fluid soaked lining/pad.
1. Replace in axle sets.
2. Loose wheel bearings, loose (or distort-
ed) mounting plate on the rear or front
axle or loose spring bolts.
2. Adjust the wheel bearing, tighten (or re-
place) the mounting plate to the axle
and tighten the spring bolts.
3. Linings/pads not of the recommended
kind.
3. Install recommended linings/pads.
Install the shoes correctly.
4. Tires not properly or evenly inflated or
unequal wear of tread.
Different tread non-skid design.
4. Inflate the tires to recommended pres-
sures. Rearrange the tires so that a pair
of non-skid tread surfaces of similar de-
sign and equal wear will be installed on
the front wheels, and an other pair with
like tread will be installed on the rear
wheels.
5. Water, mud, etc., in the brakes.
5. Remove any foreign material from all of
the brake parts and inside of the drums.
PROBLEM
POSSIBLE CAUSE
CORRECTION
00-4 SERVICE INFORMATION
Pulls to One Side
(Cont.)
6. Wheel cylinder sticking.
6. Repair or replace the wheel cylinder.
7. Weak or broken shoe return spring.
7. Check the spring-replace distorted,
open coiled, or cracked spring.
8. Out-of-round drums or different sized
drums on the same axle.
8. Refinish or replace the drums in axle
pairs.
9. Brake dragging.
9. Check for loose lining. Adjust. (Refer to
“Dragging Brakes”.)
10. Weak chassis springs, loose U-bolts,
loose steering gear, etc.
10. Replace the spring, tighten the
U-bolts, adjust the steering gear, etc.
11. Loose steering.
11. Repair and adjust.
12. Unequal camber.
12. Adjust to specifications.
13. Restricted brake line or hose.
13. Check for soft hose or damaged lines.
Replace as necessary.
14. Wheel cylinder size different on oppo-
site sides.
14. Replace with correct cylinders.
15. Loose kingpin.
15. Replace the kingpins or bushing.
16. Distorted, damaged, or scored drum/
disc.
16. Refinish the drums/discs in axle pairs.
Replace if necessary.
17. Front end alignment.
17. AIign the front end.
18. Excessively worn lining/pad.
18. Replace in axle sets.
19. Uneven adjustment of brake lining
clearance.
19. Adjust the brake lining clearance in all
wheels.
20. Water/wet linings.
20. Apply the brakes a few times while
moving at a slow speed to dry the lin-
ings.
One Wheel Locks
1. Gummy lining/pad.
1. Replace in axle sets.
2. Tire tread slick.
2. Match up tire treads from side to side.
3. Brake adjustment not correct.
3. Adjust the brakes.
4. Restricted brake line or hoses.
4. Check for soft hoses or damaged lines.
Replace as necessary.
5. Incorrect lings/pads.
5. Replace. Linings/pads must be the
same on the axle.
6. Grease or fluid soaked lining/pads.
6. Replace in axle sets.
7. Foreign material in the brakes.
7. Remove the material.
Light Pedal Pressure
Brakes too Severe
(Grabby Brakes)
1. Brake adjustment not correct.
1. Adjust the brakes.
2. Loose mounting plate on the front axle.
2. Tighten the plates.
3. A small amount of grease or fluid on the
lining/pad.
3. Replace the linings/pads.
4. Incorrect lining/pad.
4. Install factory specified linings/pads.
5. Wheel bearings loose.
5. Adjust the wheel bearings.
6. Lining loose on the shoe.
6. Replace the lining or the shoe and lin-
ing.
7. Excessive dust and dirt in the drum.
7. Clean and sand the drums and linings.
8. Out-of-round drum.
8. Turn the drums in pairs or replace.
PROBLEM
POSSIBLE CAUSE
CORRECTION
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