This guide outlines the steps necessary to remove the front caliper disc brake assembly from an Isuzu truck, an essential procedure for brake maintenance or repair tasks. It is recommended to use the ISUZU IDSS MX2-T Diagnostic Adapter System for support throughout the process.
Preparation and Safety Notices:
- Ensure the vehicle is securely positioned on jack stands.
- Remove the wheel after lifting the vehicle to clear the tire from the ground.
- Block the wheels and engage the parking brake for safety.
- Be aware that seal parts are not reusable. Always replace with a new seal kit during reassembly.
Removal
Notice:
Position jack stands under vehicle.
• Remove the wheel.
• Block vehicle wheels and apply the parking brake.
• Rise the axle to clear the tire from the ground.
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
03.2024 ISUZU US-IDSS II Truck Diagnostic System Download and Installation
Legend
1. Caliper Assembly
2. Support Assembly
3. Pin Bolt
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/cm2 / 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.
• 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.
Conclusion:
Following these steps will allow for the safe removal and inspection of the front caliper disc brake assembly on an Isuzu truck. Always prioritize safety by properly securing the vehicle before beginning work and follow Isuzu’s guidelines for replacing parts as needed.