Isuzu N-Series. Service manual - part 215

HYDRAULIC BRAKES 5A-19

Notice:
Seal parts cannot be reused. When reassembling, be
sure to replace with a new seal kit.

1. Flexible hose
2. Pin bolt (Lock pin side)
3. Caliper assembly

• Slide the caliper assembly free from the inside.

4. Outer pad
5. Inner pad
6. Pad clips
7. Support assembly

• Remove the hub and disc before removing the

support assembly.

8. Wind guide

• Remove the hub and disc before removing the

wind guide.

9. Adapter

Disassembly

1. Place a piece of wood across the body assembly to

prevent piston damage.

2. Apply approximately 196 kPa (2.0 kg/cm

2

 / 28.4

psi) of compressed air to the body assembly oil
port to remove the pistons.

Inspection

1. All parts for wear distortion or other conditions and

replace as needed.

2. Inner and outer pads.

• Use a vernier caliper to measure the inner pad

and outer pad thickness.

• If the measured value is less than the specified

limit, the pads must be replaced with the repair
pad kit.

3. Piston and Cylinder Clearance.

• Use a micrometer to measure the piston diam-

eter.

• Use an inside dial indicator to measure the cyl-

inder bore.

Legend

1. Caliper Assembly
2. Support Assembly
3. Pin Bolt

3

1

2

N5A0432E

Pad Thickness

mm (in)

Standard

Limit

13 (0.51)

1 (0.04)

N5A0067E

N5A0093E

5A-20 HYDRAULIC BRAKES

• Calculate the piston and cylinder bore clear-

ance.

• If the clearance exceeds the specified limit, the

piston and/or the body assembly must be re-
placed along with the repair seal kit.

Reassembly

1. Piston Seal

• Be sure to use a new seal ring.
• Apply rubber grease to the piston seal. The rub-

ber grease is included in the seal kit.

• Install the piston seal to the cylinder bore

groove.

2. Piston and Piston Boot

• Apply brake oil to the piston outer circumfer-

ence.

• Use a hand vise to install the pistons to the cyl-

inder.

• Apply special grease to the piston.

This will prevent cylinder and piston corrosion.

• Use a new piston boot.

Do not confuse the front and rear sides of the
boot.
Carefully press the insert portion of the boot
into the cylinder body groove. Be sure that the
insertion depth is uniform.

• Install the piston boot inner lip to the piston

groove.
Handle the piston boot carefully.

Piston and cylinder bore clearance

mm (in)

Standard

Limit

0.08 — 0.18 (0.003 — 

0.007)

0.23 (0.009)

N5A0070E

1

2

N5A0433E

Legend

1. Piston Seal
2. Body Assembly

Legend

1. Piston
2. Body Assembly
3. Hand Vise

1

2

3

N5A0434E

HYDRAULIC BRAKES 5A-21

Installation

1. Adapter

• Install the adapter to the knuckle.
• Tighten the fixing bolts and nuts to the specified

torque.

Tighten:
Fixing bolts and nuts to 162 N

⋅m (16.5 kg⋅m / 119 lb⋅ft).

2. Wind Guide

• Tighten the fixing bolts to the specified torque.

Tighten:
Fixing bolts to 13 N

⋅m (1.3 kg⋅m / 113 lb⋅in).

3. Support Assembly

• Tighten the fixing bolts to the specified torque.

Tighten:
Fixing nuts to 221 N

⋅m (22.5 kg⋅m / 163 lb⋅ft).

Legend

1. Piston Boot
2. Body Assembly
3. Cylinder Body Groove
4. Boot Insert Portion

1

1

3

4

2

N5A0435E

Legend

1. Adapter

Legend

1. Wind Guide
2. Adapter

293 mm,

310 mm

363 mm

1

1

N5A0436E

293 mm,

310 mm

363 mm

1

1

2

2

N5A0437E

5A-22 HYDRAULIC BRAKES

4. Pad Clips

• Be sure that the clips are completely installed to

the support assembly.

5. Pads

• Install the inner pad and the outer pad to the

support assembly.

6. Pin Boot

• Under normal conditions, there is no need to re-

move the pin boot.

• Apply approximately 1g (0.035 oz) of special

grease to the pin boot bore and pin boss bore
of support.
This will prevent pin corrosion.
The special grease is included in the seal kit.

• Install the pin boot to the support assembly.
• Check that the pin boot is securely inserted to

the groove.

Legend

1. Support Assembly

Legend

1. Pad Clip

1

N5A0438E

1

N5A0439E

Legend

1. Outer Pad (WEAR INDICATOR....ø310 / ø363)
2. Inner Pad (WEAR INDICATOR....ø293)
3. Support Assembly

1

2

3

N5A0440E

1

2

3

4

N5A0441E