Isuzu Amigo / Axiom / Trooper / Rodeo / VehiCross. Manual - part 198

5C–109

POWER–ASSISTED BRAKE SYSTEM

Disassembly

1. Remove guide bolt.
2. Remove lock bolt.
3. Remove dust boot; guide bolt and lock bolt.
4. Remove dust boot ring, using a small screwdriver.

302RS016

5. 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 the dust boot.
Remove piston.

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.

302RS017

6. Remove dust boot: piston.
7. Remove piston seal.
8. Remove bleeder with cap.
9. Remove caliper body.

Inspection and Repair

Make necessary parts replacement, if wear, damage,
corrosion or any other abnormal conditions are found
through inspection.
Check the following parts:

D

Rotor

D

Cylinder body

D

Cylinder bore

D

Piston

D

Guide bolt, lock bolt

D

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.

Reassembly

1. Install caliper body.
2. Install bleeder with cap and tighten the cap to the

specified torque.

Torque: 8 N·m (69 lb ft)

3. Install piston seal and 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.

302RS018

4. When inserting the piston into the cylinder, use finger

pressure only and do not use a mallet or other impact
tool, since damage to the cylinder wall or piston seal
can result.
Install piston.

5C–110 POWER–ASSISTED BRAKE SYSTEM

302RS019

5. Apply special grease (approximately 1g) to the piston

and attach the dust boot to the piston and caliper.
Insert the dust boot ring into the dust boot.

302RS020

6. Install guide bolt and lock bolt dust boot.
7. Install the dust boot on the support bracket after

applying special grease (Approx. 1g) onto the dust
boot inner surface. Also apply special grease onto the
lock bolt and guide bolt setting hole of the support
bracket.

302RS021

8. Install lock bolt and guide bolt and tighten the bolt to

the specified torque.

Torque: 44 N·m (32 lb ft)

5C–111

POWER–ASSISTED BRAKE SYSTEM

Main Data and Specifications (4

×

4 Model)

General Specifications

Type

Floating, pin slide

Pad dimension

33 cm

@

 (5.11 in

@

)

Adjusting method

Self–adjusting

Piston diameter

41.3 mm (1.63 in)

Disc type

Ventilated

Disc thickness

18 mm (0.71 in)

Disc effective diameter

269.2 mm (10.60 in)

Torque Specifications

E05RW005

5C–112 POWER–ASSISTED BRAKE SYSTEM

Brake Lining

Brake Lining and Associated Parts

305RW001

Legend

(1) Wheel and Tire Assembly
(2) Drum
(3) Hold-down Spring and Cup
(4) Hold-down Spring and Cups
(5) Lower Return Spring
(6) Upper (other) Return Spring
(7) Trailing Shoe Assembly with Parking Brake

Lever

(8) Leading Shoe Assembly with Upper (inner)

Return Spring

(9) Upper (inner) Return Spring

(10) Auto Adjuster Lever

(11) Parking Brake Lever

(12) Adjuster Assembly
(13) Wave Washer
(14) Retainer
(15) Hold-down Pin
(16) Hold-down Pin

Removal

1. Raise the vehicle and support with suitable safety

stands.

2. Remove wheel and tire assembly (1).

D

Refer to 

Wheel and Tires in Wheel and Tire System

section.

3. Remove Drum (2).

D

If difficulty is encountered in removing the drum:

– Mark the position of the drum to the axle.
– Make sure the parking brake is released.

– Use a rubber mallet to tap gently on the outer rim of

the drum and/or around the inner drum. Be careful
to avoid damaging the drum.

4. Remove upper (other) return spring (6) and auto

adjuster lever.

5. Remove lower return spring (5).
6. Remove hold-down spring and cups (4) and

hold-down pin (15).

7. Remove adjuster assembly (12)
8. Remove leading shoe assembly (8) with upper (inner)

return spring (9).