Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual - part 991

BRAKES  5-35

  INSPECTION AND REPAIR

Make necessary correction or parts replacement if wear damage or any other abnormal conditions are found
through inspection.

•

 Rotor

•

 Caliper body

•

 Cylinder bore

•

 Piston

•

 Support bracket

•

 Lock bolt

•

 Guide pin

Visual Check

Inspect the following parts for wear, bending, distortion,
cracking, corrosion, or other abnormal conditions.

Rotor

•

Thickness (t)

mm(in)

Standard

Minimum

thickness after

refinishing

Replacement

thickness

(Discard)

22.0(0.866)

20.97(0.826)

20.6(0.811)

•

Run out

Limit

mm(in)

0.13 (0.005)

Before inspection, adjust the wheel bearing correctly.
Using a dial gauge, measure the run out at the center of disc
pad contact surface.

•

Parallelism (Total circumferential thickness variation)

Limit

mm(in)

0.15 (0.0006)

Contact surface must be within 0.015 mm at the circumference
of 203 mm dia. Circle.

5-36  BRAKES

Thickness of Disc Pad

Thickness (t)

mm(in)

Standard

Limit

10.5 (0.413)

9.5 (0.374)

(For Australia only)

1.0 (0.039)

Replace the front disc pad whenever the pad wear indicator
makes a squeaking noise or when the pad is worn to within 1
mm of the shoe table.

All four brake pads should be replaced together.

Seal and Boot

The dust seal, dust boot and ring seal are to be replaced each
time the caliper is overhauled.
Discard thee used rubber parts.

BRAKES  5-37

  REASSEMBLY

CALIPER ASSEMBLY

Disassembly Steps

▲

1. Body ; caliper

▲

2. Ring seal

▲

3. Piston

▲

4. Dust seal ; piston

▲

5. Dust seal ring

▲

6. Dust boot ; sleeve

▲

7. Dust boot ; guide pin
8. Sleeve

▲

9. Bleeder with cap

Important Operations

1. Body ; Caliper

2. Ring Seal
Apply special grease to the ring seal and cylinder wall, then
insert the ring seal into the cylinder.
The special grease is included in the repair kit.

5-38  BRAKES

3. Piston
When inserting the piston into the cylinder, use finger pressure
only.
Do not use a mallet or other impact tools, since damage to the
cylinder wall or ring seal can result.

4. Dust Seal ; Piston

5. Dust Seal Ring
Apply special grease (Approx. 1g) to the piston and attach the
dust seal to the piston and caliper.
Insert the dust seal ring into the dust seal.

6. Dust Boot ; Sleeve

7. Dust Boot ; Guide Pin
Install the sleeve dust boot on the caliper after applying special
grease (Approx. 1g) into the sleeve and guide pin boot, then
insert the sleeve into the dust boot.

9. Bleeder with Cap

Torque

N

⋅

m(kgf

⋅

m/Ib

⋅

ft)

5.9-8.8 (0.6 - 0.9 / 4.3 - 6.5)