Isuzu N-Series. Manual — part 230
HYDRAULIC BRAKES 5A-79
Disassembly of lever spring
1. Fit the waste cloth between the lever and spring
not to damage each parts.
2. After running the lever up on the bracket, turn the
lever to the direction at the connecting point of le-
ver and spring.
3. Disassemble the lever from the bracket.
Drum inside diameter 370 mm
1. Remove the adjusting screw (1).
2. Remove the adjuster gear and nut assembly (2).
3. Remove the washer (SUS) (3).
4. Remove the washer (OIL LESS) (4).
Legend
1. Attach the lever to the bracket
N5A0245E
N5A0246E
Legend
1. Reassemble the lever from the direction
2. Connecting point of lever and spring
N5A0247E
N5A0248E
5A-80 HYDRAULIC BRAKES
5. Remove the return spring (1).
Remove the spring from lever side and cylinder
side.
6. Remove the lever (2).
7. Remove the snap ring (1).
8. Remove the wave washer (2).
9. Remove the washer (3).
10. Remove the pin (4).
11. Remove the spring assembly (5).
Pull out the pin from lever and separate the spring.
For piston side, remove it from flange groove of
piston.
12. Remove the piston (1).
Remove the boot from cylinder and pull out the pis-
ton.
13. Remove the boot (2).
14. Remove the piston cup (3).
15. Remove the cylinder assembly.
16. Remove the boot (1).
17. Remove the piston (2).
18. Remove the piston cup (3).
1
2
3
4
N5A0449E
2
1
N5A0450E
1
2
3
4
5
N5A0451E
1
2
3
N5A0452E
HYDRAULIC BRAKES 5A-81
19. Remove the bleeder.
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
Drum Inside Diameter 260 mm
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.
3. Boot
4. Piston Assembly
Wheel Cylinder and Piston Clearance
mm (in)
Wheel Cylinder size
Limit
28.6 (1.125)
30.2 (1.188)
25.4 (1.000)
33.3 (1.313)
0.15 (0.006)
1
2
3
N5A0453E
Legend
1. Cylinder body bore
2. Groove
3. Boot
N5A0249E
N5A0236E
5A-82 HYDRAULIC BRAKES
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.
5. Adjuster Gear
6. Adjusting Screw
Apply a coat of molybdenum disulfide grease to the
adjusting screw slit and threads.
Plain washer
Make sure to assemble the plain washer of coating side
to the adjust side.
Assemble the plain washer with the copper-colored sur-
face facing inward and the coating (black) surface facing
outward.
Notice:
Failure to assemble the plain washer or assembling it in-
side out causes auto adjuster not to operate properly.
Be sure to assemble it correctly.
7. Adjuster Lever
8. Fitting
9. Overtravel Spring
Legend
1. Piston cup
2. Piston
3. Boot
4. Grease
N5A0238E
Legend
1. Adjuster lever
2. Overtravel spring
N5A0265E
N5A0256E
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