Isuzu Trooper (1998-2002 year). Service manual — part 227
5C – 60 POWER ASSISTED BRAKE SYSTEM
3. Lock Bolt
4. Guide Bolt
4
3
5. Caliper Assembly
6
Support Bracket
•
Take care not to damage the flexible brake hose
when removing the support bracket.
7. Pad Assembly with Shim
•
Mark the lining locations if they are to be
reinstalled.
8. Clip
INSTALLATION
8. Clip
Clip
7. Pad Assembly with Shim
•
Apply special grease (approx. 0.2 g) to both
contacting surfaces of inner shims. Wipe off
extruded grease after installing.
Inner shim
Wear indicator
6. Support Bracket
Support Bracket Torque
N·m (kg·m / lb·ft)
104 (10.6 / 77)
5. Caliper Assembly
POWER ASSISTED BRAKE SYSTEM 5C – 61
4. Guide Bolt
3. Lock Bolt
Lock Bolt Torque
N·m (kg·m / lb·ft)
44 (4.5 / 32)
3
4
2. Brake Flexible Hose
1) Always use new gaskets.
2) Be sure to put the hooked edge of the flexible
hose end into the anti-rotation cavity.
Brake Flexible Hose Torque
N·m (kg·m / lb·ft)
35 (3.5 / 26)
Hooked edge
Gasket
1. Wheel and Tire Assembly
1) Refer to Wheels and Tires in Suspension section.
2) Bleed brakes.
5C – 62 POWER ASSISTED BRAKE SYSTEM
REBUILDING THE CALIPER
3
4
6
5
7
9
1
2
3
8
Disassembly Steps
1.
Guide bolt
2.
Lock bolt
3.
Dust boot
4.
Dust boot ring
5.
Piston
6.
Dust boot; piston
7.
Piston seal
8.
Bleeder with cap
9.
Caliper body
Reassembly Steps
9.
Caliper body
8.
Bleeder with cap
7.
Piston seal
5.
Piston
6.
Dust boot; pisotn
4.
Dust boot ring
3.
Dust boot
2.
Lock bolt
1.
Guide bolt
DISASSEMBLY
1. Guide Bolt
2. Lock Bolt
3. Dust Boot
4. Dust Boot Ring
•
Using a small screwdriver, remove the dust boot
ring.
POWER ASSISTED BRAKE SYSTEM 5C – 63
5. Piston
•
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 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.
6. Dust Boot; Piston
7. Piston Seal
8. Bleeder with Cap
9. Caliper Body
REASSEMBLY
9. Caliper Body
8. Bleeder with Cap
Bleeder Torque
N·m (kg·cm / lb·in)
8 (80 / 69)
7. Piston Seal
•
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.
INSPECTION AND REPAIR
Make necessary parts replacement, if wear, damage,
corrosion or any other abnormal conditions are found
through inspection.
Check the following parts;
•
Rotor
•
Cylinder body
•
Cylinder bore
•
Piston
•
Slide pin
•
Support bracket
NOTE:
The piston dust seal and dust boot are to be replaced
each time the caliper is overhauled.
Discard these used rubber parts and replace with
new ones.
5. Piston
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