Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual - part 992

BRAKES  5-39

REAR DRUM BRAKE ASSEMBLY

  DISASSEMBLY

First, disassemble the brake drum. Then disassemble the rear brake assembly.
Refer to the “REAR AXLE” section for the brake drum disassembly procedure.

MAJOR COMPONENTS

Disassembly Steps

1. Brake line
2. Holding spring and cups

▲

3. Return spring ; lower
4. Return Spring ; upper

(shoe to adjust lever)

5. Return spring ; upper

(shoe to shoe)

6. Shoe assembly (primary)

7. Shoe assembly with lever
8. Retainer with pin
9. Washer ; wave

10. Lever ; auto adjust
11. Shoe assembly (secondary)
12. Adjuster assembly
13. Wheel cylinder assembly

MINOR COMPONENTS

Disassembly Steps
Wheel Cylinder Assembly (13)

14. Boot ; wheel cylinder
15. Piston assembly
16. Cup ; piston

17. Return spring ; piston
18. Bleeder ; wheel cylinder

5-40  BRAKES

Important Operations

3. Return Spring ; Lower

  INSPECTION AND REPAIR

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

•

 Brake drum

•

 Back plate

•

 Brake lining

•

 Wheel cylinder body

•

 Piston

•

 Piston cup

•

 Return spring

Visual check

Inspect the following parts for wear scuffs, scratches,
corrosion, stains, deterioration, or other abnormal conditions.

Thickness of the Brake Lining

Thickness

mm(in)

standard (T)

Limit (t)

TFR

5.0 (0.197)

1.0 (0.039)

TFS

4.0 (0.157)

1.9 (0.039)

Inspection of the Return Spring

Free length

mm(in.)

Set length

mm(in.)

Set load

kg (Ibs.)

Holding spring

15.0 (0.591)

11.2 (0.441)

10.0

±

1.0

(22.3

±

2.2)

Wheel cylinder

spring

37.4 (1.472)

8.0 (0.315)

1.0

±

0.1

(2.2

±

0.2)

BRAKES  5-41

Free length

mm(in.)

Set length

mm(in.)

Set load

kg(lbs.)

Return spring :

upper

(adjust lever)

124.9

(4.917)

134.9

(5.311)

7

±

0.7

(15.4

±

1.6)

Shoe return

spring : upper

112.4

(4.425)

121.5

(4.783)

2

±

0.2

(4.4

±

0.4)

Shoe return

spring : lower

167.2

(6.583)

190.2

(7.488)

28.0

±

2.8

(61.7

±

6.4)

Clean wheel Cylinder Parts

Always use clean brake fluid to clean wheel cylinder parts.
Note:
Do not use mineral-vase cleaning solvents such as
gasoline, kerosene, acetone, paint thinner, or carbon
tetrachloride.

Clearance Between the Wheel Cylinder

and the Piston

mm(in)

Standard

Limit

0.02 - 0.1(0.001 - 0.004)

0.15(0.006)

Piston Cups

Inspect the piston cups for wear, distortion, fatigue, fatigue or
other abnormal conditions.

Measuring the Brake Drum

mm(in)

Standard

Limit

Inside diameter

254(10.000)

255.5(10.059)

Run out

0.05(0.002)

0.15(0.006)

Inside diameter

295(11.614)

296.5(11.673)

Run out

0.05(0.02)

0.15(0.006)

TFS

TFR

5-42  BRAKES

  REASSEMBLY

MINOR COMPONENTS

Reassembly Steps
Wheel cylinder Assembly (7)

▲

1. Bode ; wheel cylinder
2. Return spring ; piston
3. Cup ; piston

▲

4. Piston assembly
5. Boot ; wheel cylinder

▲

6. Bleeder ; wheel cylinder

MAJOR COMPONENTS

Reassembly Steps

▲

7. Wheel cylinder assembly
8. Adjuster assembly
9. Shoe assembly (secondary)

10. Lever ; auto adjuster
11. Washer ; wave
12. Retainer with pin
13. Shoe assembly (primary)

14. Return spring ; upper

(shoe to shoe)

15. Return spring ; upper

(shoe to adjust lever)

16. Return spring ; lower
17. Holding spring and cups

▲

18. Brake line