Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual - part 994

BRAKES  5-47

  DISASSEMBLY

Disassembly Steps

1. Dust seal
2. Screw
3. Reservoir ; fluid, brake
4. Grommet

▲

5. Ring ; snap

▲

6. Bolt ; stopper

7. Gasket

▲

8. Piston assembly ; primary and spring

▲

9. Piston assembly ; secondary and spring

10. Cover ; fluid reservoir
11. Seal
12. Cylinder assembly ; brake, master

5-48  BRAKES

Important Operations

When disassembling, inspecting or reassembling the master
cylinder assembly, take care not to bring the parts into contact
with mineral oil or dust. Wash the piston cups only with brake
fluid. Do not use gasoline or other mineral-base cleaning
solvents.

5. Ring ; Snap
Remove the snap ring from the cylinder body with pushing in
the primary and secondary pistons.

6. Bolt ; Stopper
Push in the primary and secondary pistons and remove the
stopper bolt completery from the cylinder body, then remove
the primary and secondary piston assemblies.

8. Piston Assembly ; Primary and Spring

9. Piston Assembly ; Secondary and Spring
Don’t remove the spring from the piston.

BRAKES  5-49

  INSPECTION AND REPAIR

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

•

 Cylinder inside face

•

 Piston

•

 Piston cap

•

 Piston cap spacer

•

 Return port

•

 Return spring

Visual Check

Inspect the following parts for wear, distortion, cuts, nicks,
corrosion, or other abnormal conditions.

Master Cylinder Bore Diameter

Standard

mm(in)

23.81 (0.938)

Clearance between the Master Cylinder

and the Piston

Measure the outer diameter of the piston assembly at the
portions shown in the left figure.

mm(in)

Standard

Limit

0.04 - 0.125

(0.00158 - 0.00493)

0.15 (0.00591)

Note:
If the clearance deviates from the range shown above,
replace the master cylinder and the piston assembly
together.

5-50  BRAKES

Return Port

Check the return port for obstructions and if necessary, clean
with a tag wire.
Blow away foreign matter with compressed air.

Primary Piston

After reassembly, push in the primary piston to see that returns
smoothly.
Repeat the test two or three times to see that brake fluid is
forced out from the front and rear outlets.